Method and apparatus for inferring item position based on multiple data

ABSTRACT

A method and apparatus which determine the location of one component on an article relative to a datum position on the article at a first location in the manufacturing process and then subsequently locating the datum position on the article at a second location in the manufacturing process and determining if the distance from another component to the datum position. The location of two components relative to one another can be determined by comparing their positions relative to the datum position. In a manufacturing process for producing articles such as children&#39;s training pants, cameras and a radiation source can be utilized to determine the positions of fastening components on the training pants when they are hidden within the pants.

[0001] This application claims the benefit of provisional applicationserial No. 60/362,833, filed Mar. 9, 2002, provisional application Ser.No. 10/094,404, filed Mar. 9, 2002, provisional application serial No.60/364,264, filed Mar. 14, 2002, provisional application serial No.60/364,329, filed Mar. 14, 2002, and of provisional application serialNo. 60/382,812, filed May 23, 2002, all of which are hereby incorporatedby reference in their entirety for all purposes.

FIELD OF THE INVENTION

[0002] The present invention relates to method and apparatus forinferring the location of an item based on comparison of multiple datasets and, more particularly, inspecting composite products sequentiallyin a continuous fabrication and assembly process to determine ifcomponents of the products are in the desired location upon completionof fabrication of the products when some of the components are notalways visible.

BACKGROUND OF THE INVENTION

[0003] Various products are fabricated in a continuous production lineby the sequential addition of components to previously suppliedcomponents. One such continuous production process is the constructionof disposable absorbent articles such as training pants, diapers,incontinence devices, etc., where components such as mechanicalfasteners are assembled as part of the article in the productionprocess. Mechanical fasteners, particularly hook and loop type fastenersnot only form part of the finished article, but must be properly alignedduring folding of the components of the article so that the finishedarticle, such as a training pant, will stay fastened when placed on awearer.

[0004] Garments, and more particularly disposable absorbent garments,have numerous applications including diapers, training pants, femininecare products, and adult incontinence products. A typical disposableabsorbent garment is formed as a composite structure including anabsorbent assembly disposed between a liquid permeable bodyside linerand a liquid impermeable outer cover. These components can be combinedwith other materials and features such as elastic materials andcontainment structures to form a product which is specifically suited toits intended purposes. A number of such garments include fasteningcomponents which are intended to be secured together (e.g.,pre-fastened) during manufacture of the garment so that the product ispackaged in its fully assembled form.

[0005] For example, one such pre-fastened garment is a child's trainingpants, which have a central absorbent chassis and front and back sidepanels extending laterally out from the chassis adjacent longitudinallyopposite ends thereof. Each of the front and back side panels has afastening component thereon, such as a hook or a loop fastener. Duringmanufacture of the training pants, the central absorbent chassis isinitially formed generally flat and then folded over so that the frontand back side panels face each other. The respective fasteningcomponents of the front and back side panels are then aligned andengaged with each other to pre-fasten the training pants in its fullyassembled three-dimensional form.

[0006] However, existing techniques for making conventional garmentssuch as the training pants described above or other pre-fastenedgarments which engage fastening components together during manufactureare in some respects inadequate. For example, weak engagement strengthbetween hook and loop fasteners, partial or whole separation of thefastening components during manufacture and packaging problems resultingfrom poorly fastened or otherwise unfastened components may be some ofthe shortcomings of existing pre-fastened garment making techniques. If,for example, the hook and loop fastening components are not properlyaligned so that they have the necessary engagement as the result of thehook and loop fastening components being laterally misaligned when thegarment is folded, the garment may not stay fastened unless the hook andloop fastening components are re-fastened by hand which might beperceived by a customer as a defective product. There is a need,therefore, for apparatus and methods which can determine at a point inthe production cycle if, for example, a folded garment has the properalignment between fastening components or should be rejected.

SUMMARY OF THE INVENTION

[0007] The present invention overcomes the above-described difficultiesand disadvantages associated with prior art manufacturing processes byproviding methods and apparatus which determine the location of acomponent or components on an article relative to a datum position onthe article at a first location in the manufacturing process and thensubsequently locating the datum position on the article at anotherlocation in the manufacturing process and determining if the distancefrom the component to the datum position determined in the firstlocation is within a predetermined range of acceptable positions at thesecond location.

[0008] Generally, a method for determining the relative placement ofcomponents on an article in a manufacturing process of the presentinvention includes establishing a datum position on the article andlocating the datum position at a first location in the manufacturingprocess. A first distance from a first of the components to the datumposition is determined at the first location in the manufacturingprocess. The datum position on the article is located at a secondlocation in the manufacturing process, as is a second of the componentsat the second location. A second distance from the datum position in thesecond location in the manufacturing process to the second component atthe second location in the manufacturing process is determined. Therelative position of the first and second components is inferred fromthe first and second determined distances, and compared to a desiredrange of relative positions to determine if this distance is within adesired range.

[0009] In another aspect of the present invention, apparatus forconstructing an article from a plurality of components and determiningif at least two of the components are positioned within a desired rangeof positions comprises an assembly line for joining multiple componentsto form an article. The assembly line includes a first inspectionstation for determining a first distance of a first of the components onan article being constructed from a datum position on the article and asecond inspection station remote from the first inspection station anddown stream in the assembly line therefrom for determining a seconddistance of the datum position on the article from a second of thecomponents at the second inspection station. A logic circuit comparesthe first distance and second distance to determine the relativelocations of the first and second components in the second location.

[0010] In a still further aspect of the present invention, apparatus fordetermining the relative placement of components on an article in amanufacturing process in reference to a datum position on the article,comprises means for locating the datum position and a first of thecomponents at a first location in the manufacturing process and meansfor determining the distance from the first component to the datumposition at the first location in the manufacturing process. Means isfurther provided for locating the datum position and a second of thecomponents on the article at a second location in the manufacturingprocess. Means determines the distance from the datum position in thesecond location in the manufacturing process to the second component atthe second location in the manufacturing process. Means compares thedetermined distance from the first component to the datum position atthe first location in the manufacturing process to a predetermineddesired range of distances from the datum to the second componentposition in the second location in the manufacturing process todetermine if this distance is within the desired range.

[0011] Definitions

[0012] Within the context of this specification, each term or phrasebelow will include the following meaning or meanings.

[0013] “Bonded” refers to the joining, adhering, connecting, attaching,or the like, of two elements. Two elements will be considered to bebonded together when they are bonded directly to one another orindirectly to one another, such as when each is directly bonded tointermediate elements.

[0014] “Comprising” is inclusive or open-ended and does not excludeadditional, unrecited elements or method steps.

[0015] “Connected” refers to the joining, adhering, bonding, attaching,or the like, of two elements. Two elements will be considered to beconnected together when they are connected directly to one another orindirectly to one another, such as when each is directly connected tointermediate elements.

[0016] “Disposable” refers to articles which are designed to bediscarded after a limited use rather than being laundered or otherwiserestored for reuse.

[0017] “Disposed,” “disposed on,” and variations thereof are intended tomean that one element can be integral with another element, or that oneelement can be a separate structure bonded to or placed with or placednear another element.

[0018] “Elastic,” “elasticized” and “elasticity” mean that property of amaterial or composite by virtue of which it tends to recover itsoriginal size and shape after removal of a force causing a deformation.

[0019] “Elastomeric” refers to a material or composite which can beelongated by at least 25 percent of its relaxed length and which willrecover, upon release of the applied force, at least 10 percent of itselongation. It is generally preferred that the elastomeric material orcomposite be capable of being elongated by at least 100 percent, morepreferably by at least 300 percent, of its relaxed length and recover,upon release of an applied force, at least 50 percent of its elongation.

[0020] “Fabrics” is used to refer to all of the woven, knitted andnonwoven fibrous webs.

[0021] “Flexible” refers to materials which are compliant and which willreadily conform to the general shape and contours of the wearer's body.

[0022] “Force” includes a physical influence exerted by one body onanother which produces acceleration of bodies that are free to move anddeformation of bodies that are not free to move. Force is expressed ingrams per unit area.

[0023] “Graphic” refers to any design, pattern, or the like that isvisible on an absorbent article.

[0024] “Hydrophilic” describes fibers or the surfaces of fibers whichare wetted by the aqueous liquids in contact with the fibers. The degreeof wetting of the materials can, in turn, be described in terms of thecontact angles and the surface tensions of the liquids and materialsinvolved. Equipment and techniques suitable for measuring thewettability of particular fiber materials or blends of fiber materialscan be provided by a Cahn SFA-222 Surface Force Analyzer System, or asubstantially equivalent system. When measured with this system, fibershaving contact angles less than 90° are designated “wettable” orhydrophilic, while fibers having contact angles greater than 90° aredesignated “nonwettable” or hydrophobic.

[0025] “Integral” is used to refer to various portions of a singleunitary element rather than separate structures bonded to or placed withor placed near one another.

[0026] “Inward” and “outward” refer to positions relative to the centerof an absorbent article, and particularly transversely and/orlongitudinally closer to or away from the longitudinal and transversecenter of the absorbent article.

[0027] “Layer” when used in the singular can have the dual meaning of asingle element or a plurality of elements.

[0028] “Liquid impermeable”, when used in describing a layer ormulti-layer laminate, means that a liquid, such as urine, will not passthrough the layer or laminate, under ordinary use conditions, in adirection generally perpendicular to the plane of the layer or laminateat the point of liquid contact. Liquid, or urine, may spread or betransported parallel to the plane of the liquid impermeable layer orlaminate, but this is not considered to be within the meaning of “liquidimpermeable” when used herein.

[0029] “Longitudinal” and “transverse” have their customary meaning. Thelongitudinal axis lies in the plane of the garment and is generallyparallel to a vertical plane that bisects a standing wearer into leftand right body halves when the article is worn. The transverse axis liesin the plane of the article generally perpendicular to the longitudinalaxis. The garment as illustrated is longer in the longitudinal directionthan in the transverse direction.

[0030] “Member” when used in the singular can have the dual meaning of asingle element or a plurality of elements.

[0031] “Nonwoven” and “nonwoven web” refer to materials and webs ofmaterial which are formed without the aid of a textile weaving orknitting process.

[0032] “Operatively joined,” with reference to the attachment of anelastic member to another element, means that the elastic member whenattached to or connected to the element, or treated with heat orchemicals, by stretching, or the like, gives the element elasticproperties; and with reference to the attachment of a non-elastic memberto another element, means that the member and element can be attached inany suitable manner that permits or allows them to perform the intendedor described function of the joinder. The joining, attaching, connectingor the like can be either directly, such as joining either memberdirectly to an element, or can be indirectly by means of another memberdisposed between the first member and the first element.

[0033] “Outer cover graphic” refers to a graphic that is directlyvisible upon inspection of the exterior surface of a garment, and for arefastenable garment is in reference to inspection of the exteriorsurface of the garment when the fastening system is engaged as it wouldbe during use.

[0034] “Permanently bonded” refers to the joining, adhering, connecting,attaching, or the like, of two elements of an absorbent garment suchthat the elements tend to be and remain bonded during normal useconditions of the absorbent garment.

[0035] “Refastenable” refers to the property of two elements beingcapable of releasable attachment, separation, and subsequent releasablereattachment without substantial permanent deformation or rupture.

[0036] “Releasably attached,” “releasably engaged” and variationsthereof refer to two elements being connected or connectable such thatthe elements tend to remain connected absent a separation force appliedto one or both of the elements, and the elements being capable ofseparation without substantial permanent deformation or rupture. Therequired separation force is typically beyond that encountered whilewearing the absorbent garment.

[0037] “Rupture” means the breaking or tearing apart of a material; intensile testing, the term refers to the total separation of a materialinto two parts either all at once or in stages, or the development of ahole in some materials.

[0038] “Stretch bonded” refers to an elastic member being bonded toanother member while the elastic member is extended at least about 25percent of its relaxed length. Desirably, the term “stretch bonded”refers to the situation wherein the elastic member is extended at leastabout 100 percent, and more desirably at least about 300 percent, of itsrelaxed length when it is bonded to the other member.

[0039] “Stretch bonded laminate” refers to a composite material havingat least two layers in which one layer is a gatherable layer and theother layer is an elastic layer. The layers are joined together when theelastic layer is in an extended condition so that upon relaxing thelayers, the gatherable layer is gathered.

[0040] “Surface” includes any layer, film, woven, nonwoven, laminate,composite, or the like, whether pervious or impervious to air, gas,and/or liquids.

[0041] “Tension” includes a uniaxial force tending to cause theextension of a body or the balancing force within that body resistingthe extension.

[0042] “Thermoplastic” describes a material that softens when exposed toheat and which substantially returns to a nonsoftened condition whencooled to room temperature.

[0043] These terms may be defined with additional language in theremaining portions of the specification.

BRIEF DESCRIPTION OF THE DRAWINGS

[0044]FIG. 1 is a side perspective of a child's training pants with afastening system of the training pants shown connected on one side ofthe training pants and disconnected on the other side of the trainingpants;

[0045]FIG. 2 is a bottom plan view of the training pants of FIG. 1 in anunfastened, stretched and laid flat condition to show an outer surfaceof the training pants which faces away from the wearer;

[0046]FIG. 3 is a top plan view of the training pants in its unfastened,stretched and laid flat condition to show an inner surface of thetraining pants which faces the wearer when the training pants are worn,with portions of the training pants being cut away to reveal underlyingfeatures;

[0047]FIG. 4 is a schematic of an assembly section of apparatus formaking articles such as training pants;

[0048]FIG. 5 is a schematic side elevation of a folding section of theapparatus for making articles such as training pants;

[0049]FIG. 6 is a schematic side elevation of a seaming section of theapparatus for making articles such as training pants;

[0050]FIG. 7 is a schematic of a portion of a continuously movingassemblage at one location along the assembly section of FIG. 4;

[0051]FIG. 8 is an enlarged side elevation of the folding section ofFIG. 5;

[0052]FIG. 9 is a top plan view of a portion of the folding section ofFIG. 5;

[0053]FIG. 10 is an enlarged fragmentary section view of a portion of apair of training pants at a location within the folding section of FIG.5;

[0054]FIG. 11 is an enlarged side elevation of an upstream portion ofthe seaming section of FIG. 6;

[0055]FIG. 12 is an enlarged side elevation of a downstream portion ofthe seaming section of FIG. 6;

[0056]FIG. 13 is a top plan view of a lower portion of the seamingsection of FIG. 6;

[0057]FIG. 14 is a partial section taken in the plane of line 14-14 ofFIG. 11;

[0058]FIG. 15 is a partial section taken in the plane of line 15-15 ofFIG. 11;

[0059]FIG. 16 is a partial section taken in the plane of line 16-16 ofFIG. 11;

[0060]FIG. 17 is a partial section taken in the plane of line 17-17 ofFIG. 11;

[0061]FIG. 18 is a partial section taken in the plane of line 18-18 ofFIG. 11;

[0062]FIG. 19 is a partial section taken in the plane of line 19-19 ofFIG. 12;

[0063]FIG. 20 is a partial section taken in the plane of line 20-20 ofFIG. 12;

[0064]FIG. 21 is a partial section taken in the plane of line 21-21 ofFIG. 12;

[0065]FIG. 22 is a perspective of a portion of an inspection system ofapparatus for making articles such as training pants;

[0066]FIG. 23 is an exploded perspective of the inspection system ofFIG. 22;

[0067]FIG. 24 is an end view of the downstream end of the seamingsection of FIG. 6;

[0068]FIG. 25 is a partial section of a second embodiment of a seamingsection of apparatus for making articles such as training pants, thesection being taken at a location corresponding to the section shown inFIG. 21;

[0069]FIG. 26 is a fragmentary, schematic view of the training pants ata first location showing first and second hook and loop materialfastening components and a datum line therein; and

[0070]FIG. 27 is a fragmentary, schematic view of the training pants ata second location in which the first and second fastening componentsoverlie each other and are fastened together, and illustrating positionsof the hook and loop material fastening components and the datum line.

[0071] Corresponding reference characters indicate corresponding partsthroughout the several views of the drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0072] The methods and apparatus of the present invention can be used tomake a variety of pre-fastened articles such as disposable absorbentgarments including diapers, training pants, feminine hygiene products,incontinence products, other personal care or health care garments, swimpants, athletic clothing, pants and shorts, and the like. Moreparticularly, the methods and apparatus of the present invention can beused to make articles in which at least two elements of the article areconnected together during the making thereof to assemble or “pre-fasten”the article. For ease of explanation, the methods and apparatus of thepresent invention are hereafter described in connection with makingpre-fastened child's training pants, generally indicated as 20 inFIG. 1. In particular, the methods and apparatus will be described interms of those for making pre-fastened disposable training pants asdescribed in U.S. patent application Ser. No. 09/444,083 titled“Absorbent Articles With Refastenable Side Seams” and filed Nov. 22,1999 (corresponding to PCT application WO 00/37009 published Jun. 29,2000) by A. L. Fletcher et al., the disclosure of which is incorporatedherein by reference. Training pants 20 can also be constructed using themethods and apparatus disclosed in U.S. Pat. No. 4,940,464 issued Jul.10, 1990 to Van Gompel et al.; and U.S. Pat. No. 5,766,389 issued Jun.16, 1998 to Brandon et al.; the disclosures of which are alsoincorporated herein by reference.

[0073] With reference now to the drawings, and in particular to FIG. 1,the training pants 20 are illustrated in a partially fastened conditionand comprise an absorbent chassis 32 having a front waist region 22, aback waist region 24, a crotch region 26 interconnecting the front andback waist regions, an inner surface 28 which is configured to contactthe wearer, and an outer surface 30 opposite the inner surface andconfigured to contact the wearer's clothing. With additional referenceto FIGS. 2 and 3, the absorbent chassis 32 also has a pair of laterallyopposite side edges 36 and a pair of longitudinally opposite waistedges, respectively designated front waist edge 38 and back waist edge39. The front waist region 22 is contiguous with the front waist edge38, and the back waist region 24 is contiguous with the back waist edge39.

[0074] The illustrated absorbent chassis 32 comprises a compositestructure 33 (FIG. 3), which when laid flat can be rectangular or anyother desired shape, and has a pair of laterally opposite front sidepanels 34 and a pair of laterally opposite back side panels 134extending outward therefrom. The composite structure 33 and side panels34, 134 may comprise two or more separate elements, as shown in FIG. 1,or be integrally formed. Integrally formed side panels 34, 134 andcomposite structure 33 would comprise at least some common materials,such as the bodyside liner, flap composite, outer cover, other materialsand/or combinations thereof, and could define a one-piece elastic,stretchable, or nonstretchable pants. The illustrated compositestructure 33 comprises an outer cover 40, a bodyside liner 42 (FIGS. 1and 3) connected to the outer cover in a superposed relation, anabsorbent assembly 44 (FIG. 3) disposed between the outer cover and thebodyside liner, and a pair of containment flaps 46 (FIG. 3). Theillustrated composite structure 33 has opposite ends 45 which formportions of the front and back waist edges 38 and 39, and opposite sideedges 47 which form portions of the side edges 36 of the absorbentchassis 32 (FIGS. 2 and 3). For reference, arrows 48 and 49 depict theorientation of the longitudinal axis and the transverse or lateral axis,respectively, of the training pants 20.

[0075] With the training pants 20 in the fastened position as partiallyillustrated in FIG. 1, the front and back side panels 34, 134 areconnected together by a fastening system 80 to define athree-dimensional pants configuration having an interior space 51, awaist opening 50 for receiving the wearer into the interior space of thepants, a pair of leg openings 52 and engagement seams 88 along which theside panels are connected. The interior space 51 of the pants 20 is thusbounded by the absorbent chassis 32, the engagement seams 88 and theportions of the side panels 34, 134 extending on opposite sides of theengagement seams 88 (e.g., between the engagement seams and theabsorbent chassis). As used herein, the “interior space” 51 is intendedto refer to the space between any two portions of a three-dimensionalarticle which generally oppose each other. It is understood that atransverse cross-section of the article need not be closed, e.g.,continuous, to define an interior space. For example, a two-dimensionalarticle may be generally folded over on itself so that two portions ofthe article oppose each other to define an interior space of the articletherebetween. Thus, the interior space 51 of the training pants 20 shownin FIG. 1 may be defined by the side panels 34, 134 themselves or, ifthe side panels were fully straightened therebetween, the interior spacewould be defined by a combination of the side panels and the front andback waist regions 22, 24 of the absorbent chassis 32.

[0076] The front waist region 22 comprises the portion of the trainingpants 20 which, when worn, is positioned on the front of the wearerwhile the back waist region 24 comprises the portion of the trainingpants which, when worn, is positioned on the back of the wearer. Thecrotch region 26 of the training pants 20 comprises the portion of thetraining pants 20 which, when worn, is positioned between the legs ofthe wearer and covers the lower torso of the wearer. The front and backside panels 34 and 134 comprise the portions of the training pants 20which, when worn, are positioned on the hips of the wearer. The waistedges 38 and 39 of the absorbent chassis 32 are configured to encirclethe waist of the wearer when worn and together define the waist opening50 (FIG. 1). Portions of the side edges 36 in the crotch region 26generally define the leg openings 52.

[0077] The absorbent chassis 32 is configured to contain and/or absorbany exudates discharged from the wearer. For example, the absorbentchassis 32 desirably although not necessarily comprises the pair ofcontainment flaps 46 which are configured to provide a barrier to thetransverse flow of body exudates. A flap elastic member 53 (FIG. 3) canbe operatively joined with each containment flap 46 in any suitablemanner as is well known in the art. The elasticized containment flaps 46define an unattached edge which assumes an upright configuration in atleast the crotch region 26 of the training pants 20 to form a sealagainst the wearer's body. The containment flaps 46 can be located alongthe side edges 36 of the absorbent chassis 32, and can extendlongitudinally along the entire length of the absorbent chassis or mayonly extend partially along the length of the absorbent chassis.Suitable constructions and arrangements for the containment flaps 46 aregenerally well known to those skilled in the art and are described inU.S. Pat. No. 4,704,116 issued Nov. 3, 1987 to Enloe, which isincorporated herein by reference.

[0078] To further enhance containment and/or absorption of bodyexudates, the training pants 20 desirably although not necessarilyinclude a front waist elastic member 54, a rear waist elastic member 56,and leg elastic members 58, as are known to those skilled in the art(FIG. 3). The waist elastic members 54 and 56 can be operatively joinedto the outer cover 40 and/or the bodyside liner 42 along the oppositewaist edges 38 and 39, and can extend over part or all of the waistedges. The leg elastic members 58 can be operatively joined to the outercover 40 and/or the bodyside liner 42 along the opposite side edges 36and positioned in the crotch region 26 of the training pants 20. The legelastic members 58 can be longitudinally aligned along each side edge 47of the composite structure 33. Each leg elastic member 58 has a frontterminal point 63 and a back terminal point 65, which represent thelongitudinal ends of the elastic gathering caused by the leg elasticmembers. The front terminal points 63 can be located adjacent thelongitudinally innermost parts of the front side panels 34, and the backterminal points 65 can be located adjacent the longitudinally innermostparts of the back side panels 134.

[0079] The flap elastic members 53, the waist elastic members 54 and 56,and the leg elastic members 58 can be formed of any suitable elasticmaterial. As is well known to those skilled in the art, suitable elasticmaterials include sheets, strands or ribbons of natural rubber,synthetic rubber, or thermoplastic elastomeric polymers. The elasticmaterials can be stretched and adhered to a substrate, adhered to agathered substrate, or adhered to a substrate and then elasticized orshrunk, for example with the application of heat, such that elasticconstrictive forces are imparted to the substrate. In one particularembodiment, for example, the leg elastic members 58 comprise a pluralityof dry-spun coalesced multifilament spandex elastomeric threads soldunder the trade name LYCRA® and available from E. I. Du Pont de Nemoursand Company, Wilmington, Del., U.S.A.

[0080] The outer cover 40 desirably comprises a material which issubstantially liquid impermeable, and can be elastic, stretchable ornonstretchable. The outer cover 40 can be a single layer of liquidimpermeable material, but desirably comprises a multi-layered laminatestructure in which at least one of the layers is liquid impermeable. Forinstance, the outer cover 40 can include a liquid permeable outer layerand a liquid impermeable inner layer that are suitably joined togetherby a laminate adhesive, ultrasonic bonds, thermal bonds, or the like.Suitable laminate adhesives, which can be applied continuously orintermittently as beads, a spray, parallel swirls, or the like, can beobtained from Findley Adhesives, Inc., of Wauwatosa, Wis., U.S.A., orfrom National Starch and Chemical Company, Bridgewater, N.J. U.S.A. Theliquid permeable outer layer can be any suitable material and desirablyone that provides a generally cloth-like texture. One example of such amaterial is a 20 gsm (grams per square meter) spunbond polypropylenenonwoven web. The outer layer may also be made of those materials ofwhich the liquid permeable bodyside liner 42 is made. While it is not anecessity for the outer layer to be liquid permeable, it is desired thatit provides a relatively cloth-like texture to the wearer.

[0081] The inner layer of the outer cover 40 can be both liquid andvapor impermeable, or can be liquid impermeable and vapor permeable. Theinner layer can be manufactured from a thin plastic film, although otherflexible liquid impermeable materials may also be used. The inner layer,or the liquid impermeable outer cover 40 when a single layer, preventswaste material from wetting articles, such as bedsheets and clothing, aswell as the wearer and caregiver. A suitable liquid impermeable film foruse as a liquid impermeable inner layer, or a single layer liquidimpermeable outer cover 40, is a 0.02 millimeter polyethylene filmcommercially available from Pliant Corporation of Schaumburg, Ill.U.S.A.

[0082] If the outer cover 40 is a single layer of material, it can beembossed and/or matte finished to provide a more cloth-like appearance.As earlier mentioned, the liquid impermeable material can permit vaporsto escape from the interior space 51 of the disposable absorbentarticle, while still preventing liquids from passing through the outercover 40. A suitable “breathable” material is composed of a microporouspolymer film or a nonwoven fabric that has been coated or otherwisetreated to impart a desired level of liquid impermeability. A suitablemicroporous film is a PMP-1 film material commercially available fromMitsui Toatsu Chemicals, Inc., Tokyo, Japan, or an XKO-8044 polyolefinfilm commercially available from 3M Company, Minneapolis, Minn. U.S.A.

[0083] As shown in FIGS. 1 and 2, the training pants 20 and inparticular the outer cover 40 desirably comprises one or moreappearance-related components. Examples of appearance-related componentsinclude, but are not limited to, graphics; highlighting or emphasizingleg and waist openings in order to make product shaping more evident orvisible to the user; highlighting or emphasizing areas of the product tosimulate functional components such as elastic leg bands, elasticwaistbands, simulated “fly openings” for boys, ruffles for girls;highlighting areas of the product to change the appearance of the sizeof the product; registering wetness indicators, temperature indicators,and the like in the product; registering a back label, or a front label,in the product; and registering written instructions at a desiredlocation in the product.

[0084] The illustrated pair of training pants 20 is designed for use byyoung girls and includes a registered outer cover graphic 60 (FIG. 2).In this design, the registered graphic 60 includes a primary pictorialimage 61, simulated waist ruffles 62, and simulated leg ruffles 64. Theprimary pictorial image 61 includes a rainbow, sun, clouds, animalcharacters, wagon and balloons. Any suitable design can be utilized fora training pants intended for use by young girls, so as to beaesthetically and/or functionally pleasing to them and the caregiver.The appearance-related components are desirably positioned on thetraining pants 20 at selected locations, which can be carried out usingthe methods disclosed in U.S. Pat. No. 5,766,389 issued Jun. 16, 1998 toBrandon et al., the entire disclosure of which is incorporated herein byreference. The primary pictorial image 61 is desirably positioned in thefront waist region 22 along the longitudinal center line of the trainingpants 20.

[0085] The liquid permeable bodyside liner 42 is illustrated asoverlying the outer cover 40 and absorbent assembly 44, and may but neednot have the same dimensions as the outer cover 40. The bodyside liner42 is desirably compliant, soft feeling, and non-irritating to thechild's skin. Further, the bodyside liner 42 can be less hydrophilicthan the absorbent assembly 44, to present a relatively dry surface tothe wearer and permit liquid to readily penetrate through its thickness.Alternatively, the bodyside liner 42 can be more hydrophilic or can haveessentially the same affinity for moisture as the absorbent assembly 44to present a relatively wet surface to the wearer to increase thesensation of being wet. This wet sensation can be useful as a trainingaid. The hydrophilic/hydrophobic properties can be varied across thelength, width and depth of the bodyside liner 42 and absorbent assembly44 to achieve the desired wetness sensation or leakage performance.

[0086] The bodyside liner 42 can be manufactured from a wide selectionof web materials, such as synthetic fibers (for example, polyester orpolypropylene fibers), natural fibers (for example, wood or cottonfibers), a combination of natural and synthetic fibers, porous foams,reticulated foams, apertured plastic films, or the like. Various wovenand nonwoven fabrics can be used for the bodyside liner 42. For example,the bodyside liner can be composed of a meltblown or spunbonded web ofpolyolefin fibers. The bodyside liner can also be a bonded-carded webcomposed of natural and/or synthetic fibers. The bodyside liner can becomposed of a substantially hydrophobic-material, and the hydrophobicmaterial can, optionally, be treated with a surfactant or otherwiseprocessed to impart a desired level of wettability and hydrophilicity.For example, the material can be surface treated with about 0.45 weightpercent of a surfactant mixture comprising Ahcovel N-62 from HodgsonTextile Chemicals of Mount Holly, N.C., U.S.A. and GLUCOPON® 220UP fromThe Cognis Group of Ambler, Pa. in an active ratio of 3:1. Thesurfactant can be applied by any conventional means, such as spraying,printing, brush coating or the like. The surfactant can be applied tothe entire bodyside liner 42 or can be selectively applied to particularsections of the bodyside liner, such as the medial section along thelongitudinal center line.

[0087] A suitable liquid permeable bodyside liner 42 is a nonwovenbicomponent web having a basis weight of about 27 gsm. The nonwovenbicomponent can be a spunbond bicomponent web, or a bonded cardedbicomponent web. Suitable bicomponent staple fibers include apolyethylene/polypropylene bicomponent fiber available from CHISSOCorporation, Osaka, Japan. In this particular bicomponent fiber, thepolypropylene forms the core and the polyethylene forms the sheath ofthe fiber. Other fiber orientations are possible, such as multi-lobe,side-by-side, end-to-end, or the like. The outer cover 40, bodysideliner 42 and other materials used to construct the pants can compriseelastomeric or nonelastomeric materials.

[0088] The absorbent assembly 44 (FIG. 3) is positioned between theouter cover 40 and the bodyside liner 42, which can be joined togetherby any suitable means such as adhesives, ultrasonic bonds, thermalbonds, or the like. The absorbent assembly 44 can be any structure whichis generally compressible, conformable, non-irritating to the child'sskin, and capable of absorbing and retaining liquids and certain bodywastes, and may be manufactured in a wide variety of sizes and shapes,and from a wide variety of liquid absorbent materials commonly used inthe art. For example, the absorbent assembly 44 can suitably comprise amatrix of hydrophilic fibers, such as a web of cellulosic fluff, mixedwith particles of a high-absorbency material commonly known assuperabsorbent material. In a particular embodiment, the absorbentassembly 44 comprises a matrix of cellulosic fluff, such as wood pulpfluff, and superabsorbent hydrogel-forming particles. The wood pulpfluff can be exchanged with synthetic, polymeric, meltblown fibers orshort cut homofil bicomponent synthetic fibers and natural fibers. Thesuperabsorbent particles can be substantially homogeneously mixed withthe hydrophilic fibers or can be nonuniformly mixed. The fluff andsuperabsorbent particles can also be selectively placed into desiredzones of the absorbent assembly 44 to better contain and absorb bodyexudates. The concentration of the superabsorbent particles can alsovary through the thickness of the absorbent assembly 44. Alternatively,the absorbent assembly 44 can comprise a laminate of fibrous webs andsuperabsorbent material or other suitable means of maintaining asuperabsorbent material in a localized area.

[0089] Suitable superabsorbent materials can be selected from natural,synthetic, and modified natural polymers and materials. Thesuperabsorbent materials can be inorganic materials, such as silicagels, or organic compounds, such as crosslinked polymers, for example,sodium neutralized polyacrylic acid. Suitable superabsorbent materialsare available from various commercial vendors, such as Dow ChemicalCompany located in Midland, Mich., U.S.A., and Stockhausen GmbH & Co.KG, D-47805 Krefeld, Federal Republic of Germany. Typically, asuperabsorbent material is capable of absorbing at least about 15 timesits weight in water, and desirably is capable of absorbing more thanabout 25 times its weight in water.

[0090] In one embodiment, the absorbent assembly 44 comprises a blend ofwood pulp fluff and superabsorbent material. One preferred type of pulpis identified with the trade designation CR1654, available from U.S.Alliance, Childersburg, Ala., U.S.A., and is a bleached, highlyabsorbent sulfate wood pulp containing primarily soft wood fibers andabout 16 percent hardwood fibers. As a general rule, the superabsorbentmaterial is present in the absorbent assembly 44 in an amount of from 0to about 90 weight percent based on total weight of the absorbentassembly. The absorbent assembly 44 suitably has a density within therange of about 0.10 to about 0.35 grams per cubic millimeter. Theabsorbent assembly 44 may or may not be wrapped or encompassed by asuitable tissue wrap that may help maintain the integrity and/or shapeof the absorbent assembly.

[0091] The absorbent chassis 32 can also incorporate other materialsdesigned primarily to receive, temporarily store, and/or transportliquid along the mutually facing surface with absorbent assembly 44,thereby maximizing the absorbent capacity of the absorbent assembly. Onesuitable material is referred to as a surge layer (not shown) andcomprises a material having a basis weight of about 50 to about 120grams per square meter, and comprising a through-air-bonded-carded webof a homogenous blend of 60 percent 3 denier type T-256 bicomponentfiber comprising a polyester core/polyethylene sheath and 40 percent 6denier type T-295 polyester fiber, both commercially available from KosaCorporation of Salisbury, N.C., U.S.A.

[0092] As noted previously, the illustrated training pants 20 have frontand back side panels 34 and 134 disposed on each side of the absorbentchassis 32. The front side panels 34 can be permanently bonded alongseams 66 to the composite structure 33 of the absorbent chassis 32 inthe respective front and back waist regions 22 and 24. Moreparticularly, as seen best in FIGS. 2 and 3, the front side panels 34can be permanently bonded to and extend transversely outward beyond theside edges 47 of the composite structure 33 in the front waist region22, and the back side panels 134 can be permanently bonded to and extendtransversely outward beyond the side edges of the composite structure inthe back waist region 24. The side panels 34 and 134 may be bonded tothe composite structure 33 using attachment means known to those skilledin the art such as adhesive, thermal or ultrasonic bonding.Alternatively, the side panels 34 and 134 can be formed as an integralportion of a component of the composite structure 33. For example, theside panels can comprise a generally wider portion of the outer cover40, the bodyside liner 42, and/or another component of the absorbentchassis 32. The front and back side panels 34 and 134 can be permanentlybonded together or be releasably connected with one another such as bythe fastening system 80 of the illustrated embodiment.

[0093] The front and back side panels 34, 134 each have an outer edge 68spaced laterally from the seam 66, a leg end edge 70 disposed toward thelongitudinal center of the training pants 20, and a waist end edge 72disposed toward a longitudinal end of the training pants. The leg endedge 70 and waist end edge 72 extend from the side edges 47 of thecomposite structure 33 to the outer edges 68. The leg end edges 70 ofthe side panels 34 and 134 form part of the side edges 36 of theabsorbent chassis 32. In the back waist region 24, the leg end edges 70are desirably although not necessarily curved and/or angled relative tothe transverse axis 49 to provide greater coverage toward the back ofthe pants 20 as compared to the front of the pants. The waist end edges72 are desirably parallel to the transverse axis 49. The waist end edges72 of the front side panels 34 form part of the front waist edge 38 ofthe absorbent chassis 32, and the waist end edges 72 of the back sidepanels 134 form part of the back waist edge 39 of the absorbent chassis.

[0094] In particular embodiments for improved fit and appearance, theside panels 34, 134 desirably have an average length measured parallelto the longitudinal axis 48 which is about 20 percent or greater, andparticularly about 25 percent or greater, of the overall length of thepants, also measured parallel to the longitudinal axis 48. For example,in training pants 20 having an overall length of about 54 millimeters,the side panels 34, 134 desirably have an average length of about 10millimeters or greater, such as about 15 millimeters. While each of theside panels 34, 134 extends from the waist opening 50 to one of the legopenings 52, the illustrated back side panels 134 have a continuallydecreasing length dimension moving from the attachment line 66 to theouter edge 68, as is best shown in FIGS. 2 and 3.

[0095] Each of the side panels 34, 134 can include one or moreindividual, distinct pieces of material. In particular embodiments, forexample, each side panel 34, 134 can include first and second side panelportions that are joined at a seam, or can include a single piece ofmaterial which is folded over upon itself (not shown).

[0096] The side panels 34, 134 desirably although not necessarilycomprise an elastic material capable of stretching in a directiongenerally parallel to the transverse axis 49 of the training pants 20.Suitable elastic materials, as well as one process of incorporatingelastic side panels into training pants, are described in the followingU.S. patents: U.S. Pat. No. 4,940,464 issued Jul. 10, 1990 to Van Gompelet al.; U.S. Pat. No. 5,224,405 issued Jul. 6, 1993 to Pohjola; U.S.Pat. No. 5,104,116 issued Apr. 14, 1992 to Pohjola; and U.S. Pat. No.5,046,272 issued Sep. 10, 1991 to Vogt et al.; all of which areincorporated herein by reference. In particular embodiments, the elasticmaterial comprises a stretch-thermal laminate (STL), a neck-bondedlaminate (NBL), a reversibly necked laminate, or a stretch-bondedlaminate (SBL) material. Methods of making such materials are well knownto those skilled in the art and described in U.S. Pat. No. 4,663,220issued May 5, 1987 to Wisneski et al.; U.S. Pat. No. 5,226,992 issuedJul. 13, 1993 to Morman; and European Patent Application No. EP 0 217032 published on Apr. 8, 1987 in the names of Taylor et al.; all ofwhich are incorporated herein by reference. Alternatively, the sidepanel material may comprise other woven or nonwoven materials, such asthose described above as being suitable for the outer cover 40 orbodyside liner 42; mechanically pre-strained composites; or stretchablebut inelastic materials.

[0097] The illustrated training pants 20 includes the fastening system80 for refastenably securing the training pants about the waist of thewearer. The illustrated fastening system 80 includes first fasteningcomponents 82 adapted for refastenable engagement to correspondingsecond fastening components 84. In one embodiment, one surface of eachof the first fastening components 82 comprises a plurality of engagingelements which project from that surface. The engaging elements of thefirst fastening components 82 are adapted to repeatedly engage anddisengage engaging elements of the second fastening components 84.

[0098] The fastening components can comprise separate elements bonded tothe side panels, or they may be integrally formed with the side panels.Thus, unless otherwise specified, the term “fastening component”includes separate components which function as fasteners, and regions ofmaterials such as the side panels which function as fasteners. Moreover,a single material can define multiple fastening components to the extentthat different regions of the material function as separate fasteners.The fastening components 82, 84 can be located on the side panels,between the side panels such as on the absorbent chassis, or acombination of the two. Alternately, the fasteners may extend out fromthe side panel edges.

[0099] The fastening components 82, 84 can comprise any refastenablefasteners suitable for absorbent articles, such as adhesive fasteners,cohesive fasteners, mechanical fasteners, or the like. In particularembodiments the fastening components comprise mechanical fasteningelements for improved performance. Suitable mechanical fasteningelements can be provided by interlocking geometric shaped materials,such as hooks, loops, bulbs, mushrooms, arrowheads, balls on stems, maleand female mating components, buckles, snaps, or the like.

[0100] The refastenable fastening system 80 allows for easy inspectionof the interior space 51 of the pants 20. If necessary, the fasteningsystem 80 also allows the pants 20 to be removed quickly and easily.This is particularly beneficial when the pants contain messy excrement.For training pants 20, the caregiver can completely remove the pant-likeproduct and replace it with a new one without having to remove thechild's shoes and clothing.

[0101] In the illustrated embodiment, the first fastening components 82comprise loop fasteners and the second fastening components 84 comprisecomplementary hook fasteners. In another particular embodiment, thefirst fastening components 82 comprise hook fasteners and the secondfastening components 84 comprise complementary loop fasteners.Alternatively, the fastening components 82, 84 can comprise interlockingsimilar surface fasteners, adhesive or cohesive fastening elements suchas an adhesive fastener and an adhesive-receptive landing zone ormaterial, or the like. Although the training pants 20 illustrated inFIG. 1 show the back side panels 134 overlapping the front side panels34 upon connection thereto, which is convenient, the training pants 20can also be configured so that the front side panels overlap the backside panels when connected. One skilled in the art will recognize thatthe shape, density and polymer composition of the hooks and loops may beselected to obtain the desired level of engagement between the fasteningcomponents 82, 84. A more aggressive hook material may comprise amaterial with a greater average hook height, a greater percentage ofdirectionally-aligned hooks, or a more aggressive hook shape.

[0102] Loop fasteners typically comprise a fabric or material having abase or backing structure and a plurality of loop members extendingupwardly from at least one surface of the backing structure. The loopmaterial can be formed of any suitable material, such as acrylic, nylon,polypropylene or polyester, polyethylene and can be formed by methodssuch as warp knitting, stitch bonding or needle punching. Loop materialscan also comprise any fibrous structure capable of entangling orcatching hook materials, such as carded, spunbonded or other nonwovenwebs or composites, including elastomeric and nonelastomeric composites.Suitable loop materials are available from Guilford Mills, Inc.,Greensboro, N.C., U.S.A. under the trade designation No. 36549. Anothersuitable loop material can comprise a pattern un-bonded web as disclosedin U.S. Pat. No. 5,858,515 issued Jan. 12, 1999 to Stokes et al.

[0103] Hook fasteners typically comprise a fabric or material having abase or backing structure and a plurality of hook members extendingupwardly from at least one surface of the backing structure. In contrastto the loop fasteners which desirably comprise a flexible fabric, thehook material advantageously comprises a resilient material to minimizeunintentional disengagement of the fastener components as a result ofthe hook material becoming deformed and catching on clothing or otheritems. The term “resilient” as used herein refers to an interlockingmaterial having a predetermined shape and the property of theinterlocking material to resume the predetermined shape after beingengaged and disengaged from a mating, complementary interlockingmaterial. Suitable hook material can be molded or extruded from nylon,polypropylene, polyethylene or another suitable material. Suitablesingle-sided hook materials for the fastening components 82, 84 areavailable from commercial vendors such as Velcro Industries B.V.,Amsterdam, Netherlands or affiliates thereof, and are identified asVelcro HTH-829 with a uni-directional hook pattern and having athickness of about 0.9 millimeters (35 mils) and HTH-851 with aunidirectional hook pattern and having a thickness of about 0.5millimeters (20 mils); and Minnesota Mining & Manufacturing Co., St.Paul, Minn. U.S.A., including specific materials identified as CS-600.

[0104] With particular reference to FIG. 3, the fastening components 82are disposed on the inner surface 28 of the back side panels 134. Thefastening components 82 are desirably positioned along the outer edges68 of the back side panels 134, and abutting or adjacent to the waistend edge 72. In certain embodiments, for example, the fasteningcomponents 82 can be spaced inward from the outside edge about 0 toabout 25 millimeters, and more particularly within about 1 millimeter,of the outer edges 68, the waist end edges 72, and the leg end edges 70.With particular reference to FIG. 2, the second fastening components 84are disposed on the outer surface 30 of the front side panels 34. Thesecond fastening components 84 are sized to receive the first fasteningcomponents 82 and are desirably positioned along the outer edges 68 ofthe front side panels 34, and abutting or adjacent to the waist end edge72. As an example, the second fastening components 84 can be locatedwithin about 2 millimeters, and more particularly within about 1millimeter, of the outer edges 68, the waist end edges 72, and the legend edges 70. Where the first fastening components 82 comprise loopfasteners disposed on the inner surface 28 and the second fasteningcomponents 84 comprise hook fasteners disposed on the outer surface 30,the first fastening components can be sized larger than the secondfastening components to ensure coverage of the rigid, outwardly-directedhooks. Alternately, the hooks and loop fasteners can overhang the edgeof the side panel by offset attachment of the fasteners.

[0105] The fastening components 84, 82 can be adhered to the respectiveside panels 34, 134 by any means known to those skilled in the art suchas adhesive bonds, ultrasonic bonds or thermal bonds. The fasteningcomponents 82, 84 may comprise separate fastening elements or distinctregions of an integral material. For example, the training pants 20 caninclude an integral second fastening material disposed in the frontwaist region 22 for refastenably connecting to the first fasteningcomponents 82 at two or more different regions, which define the secondfastening components 84 (FIG. 1). In a particular embodiment, thefastening components 82, 84 can comprise integral portions of the waistregions 24, 22. For instance, one of the elastomeric front or back sidepanels 34, 134 can function as second fastening components 84 in thatthey can comprise a material which is releasably engageable withfastening components 82 disposed in the opposite waist region.

[0106] The fastening components 82, 84 of the illustrated embodimentsare rectangular, although they may alternatively be square, round, oval,curved or otherwise non-rectangularly shaped. In particular embodiments,each of the fastening components 82, 84 has a length aligned generallyparallel to the longitudinal axis 48 of the training pants 20 and awidth aligned generally parallel to the transverse axis 49 of thetraining pants. For a child of about 9 to about 15 kilograms (20-30pounds), for example, the length of the fastening components 82, 84 isdesirably from about 5 to about 13 millimeters, such as about 10millimeters, and the width is desirably from about 0.5 to about 3millimeters, such as about 1 millimeter. With particular embodiments,the fastening components 82, 84 can have a length-to-width ratio ofabout 2 or greater, such as about 2 to about 25, and more particularlyabout 5 or greater, such as about 5 to about 8. For other embodimentssuch as for adult products, it may be desirable for one or more of thefastening components to comprise a plurality of relatively smallerfastening elements. In that case, a fastening component or individualfastening elements may have an even smaller length-to-width ratio, forexample, of about 2 or less, and even about 1 or less.

[0107] As shown in FIG. 1, when the fastening components 82, 84 arereleasably connected, the side edges 36 of the absorbent chassis 32 inthe crotch region 26 define the leg openings 52, and the waist edges 38and 39 of the absorbent chassis, including the waist end edges 72 of theside panels 34, 134, define the waist opening 50. For improved formationof the leg openings 52, it can be desirable in some embodiments for thefront side panels 34 to be longitudinally spaced from the back sidepanels 134 as shown in FIGS. 2 and 3. For example, the front side panels34 can be longitudinally spaced from the back side panels 134 by adistance equal to about 20 percent or greater, particularly from about20 to about 60 percent, and more particularly from about 35 to about 50percent, of the overall length of the pants 20.

[0108] When connected, the fastening components 82, 84 of theillustrated embodiment define refastenable engagement seams 88 (FIG. 1)which desirably although not necessarily extend substantially the entiredistance between the waist opening 50 and the leg openings 52. Morespecifically, the engagement seams 88 can cover about 80 to 100 percent,and particularly about 90 to about 98 percent, of the distance betweenthe waist opening 50 and each leg opening 52, which distance is measuredparallel to the longitudinal axis 48. To construct the engagement seams88 to extend substantially the entire distance between the waist and legopenings 50 and 52, the fastening components 82, 84 can be formed tocover about 80 to 100 percent, and more particularly about 90 to about98 percent, of the distance between the waist end edge 70 and the legend edge 72 of the side panels 34, 134. In other embodiments, thefastening components can comprise a plurality of smaller fasteningelements covering a smaller portion of the distance between the waistopening 50 and the leg openings 52, for example, about 20 to about 70percent, but spaced apart to span a larger percentage of the distancebetween the waist opening and the leg openings.

[0109] For the engagement seams 88 to be located at the sides of thewearer, it can be particularly desirable for the transverse distancebetween the fastening components 82 of the back side panels 134 to besubstantially equal to the transverse distance between the fasteningcomponents 84 of the front side panel 134. The transverse distancebetween a set of fastening components 82, 84 is measured parallel to thetransverse axis 49 between the longitudinal center lines of thefastening component, measured with the side panels 34, 134 in anunstretched condition. Alternately, the fastening components 82, 84 canbe placed non-parallel to the transverse axis 49 of the pant.

[0110] FIGS. 4-6 generally illustrate apparatus of the present inventionfor making a pre-fastened article, and more particularly for making thepre-fastened, refastenable training pants 20 shown in FIG. 1. Theapparatus comprises an assembly section, generally indicated at 100 inFIG. 4, for making partially assembled training pants 102 in an unfoldedconfiguration, a folding section, generally indicated at 200 in FIG. 5,for folding the partially assembled pants generally at the crotch region26, and a seaming section, generally indicated at 250 in FIG. 6, forconnecting the fastening components 84, 82 of the respective front andback side panels 34, 134 to form the pre-fastened training pants.

[0111] The various elements of the partially assembled training pants102 can be connected together in the assembly section 100 by any meansknown to those skilled in the art such as, for example, adhesive,thermal and/or ultrasonic bonds. Desirably, most of the elements areconnected using ultrasonic bonding for improved manufacturing efficiencyand reduced raw material costs. Certain garment manufacturing equipmentwhich is readily known and understood in the art, including frames andmounting structures, ultrasonic and adhesive bonding devices, transportconveyors, transfer rolls, guide rolls, tension rolls, and the like,have not been shown in FIGS. 4 and 5. Suitable absorbent supplymechanisms, web unwinds, conveyor systems, registration systems, drivesystems, control systems and the like, for use with the presentapparatus are disclosed in U.S. Pat. No. 5,766,389 issued Jun. 16, 1998to Brandon et al., the entire disclosure of which is incorporated hereinby reference. Also, the outer cover graphics 61 are not shown in FIGS.4-7.

[0112] With particular reference to the assembly section 100 shown inFIG. 4, a continuous supply of material 104 used to form the bodysideliner 42 is provided from a supply source 106. The supply source 106 cancomprise for example any standard unwind mechanism, which generallyincludes a pair of spindles, a festoon assembly, and a dancer roll forproviding bodyside liner material 104 at a desired speed and tension.

[0113] Various elements can be disposed on and/or bonded to the bodysideliner material 104 as the material travels in a machine directionidentified by arrow 108. In particular, a surge layer can be provided atan application station 110 and disposed on and/or bonded to the bodysideliner material 104. The surge layer can comprise either a continuous webor discrete sheets. Additionally, a containment flap module 112 can beprovided downstream from the supply source 106 for attachingpre-assembled containment flaps to the bodyside liner material 104. Asvarious elements are added in the assembly section 100, a continuouslymoving product assemblage 113 is formed. The product assemblage 113 willbe cut downstream to form the partially assembled, discrete trainingpants 102.

[0114] A plurality of absorbent assemblies 114 can be provided from asuitable supply source 115. The supply source 115 can be anyconventional mechanism for supplying the absorbent assemblies 114.Generally, a conventional supply source can include a hammermill forforming fluff fibers and, if desired, for providing an enclosure formixing superabsorbent material with the fluff fibers, and thendepositing the fluff and superabsorbent material on a forming drumhaving a desired absorbent design. The individual absorbent assemblies114 can be disposed intermittently on the continuously moving bodysideliner material 104, one for each pair of training pants. The position ofthe absorbent assemblies 114 can be registered with the position of thesurge material, if employed. The absorbent assemblies 114 can be bondedto one or more other components using adhesives or other suitable means.Alternatively, composite absorbent materials can be fed into theconverting process from rolls or compressed packages.

[0115] Continuous webs of material 116 used to form the side panels 34,134 can be provided from suitable supply sources 117. The supply sources117 can comprise one or more standard unwind mechanisms. The side panelmaterial 116 can be cut into individual strips 118 and positionedpartially on the bodyside liner material 104 using an applicator device120. In the cross machine direction, the individual strips 118 desirablyextend laterally outward from the bodyside liner material 104 (see FIGS.4 and 7) and overlap the bodyside liner material by an amount such asabout 2 or more millimeters to permit bonding of the strips to thebodyside liner and/or the containment flap material. In the machinedirection 108, the position of the strips 118 can be registered relativeto the absorbent assemblies 114 so that the product assemblage 113 canbe cut between the absorbent assemblies with each strip 118 of sidepanel material 116 forming both a front side panel 34 and a back sidepanel 134 of consecutive pants 102.

[0116] One suitable applicator device 120 is disclosed in U.S. Pat. No.5,104,116 issued Apr. 14, 1992 and U.S. Pat. No. 5,224,405 issued Jul.6, 1993 both to Pohjola, which are incorporated herein by reference. Theapplicator device 120 can comprise a cutting assembly 122 and arotatable transfer roll 124. The cutting assembly 122 employs arotatable knife roll 126 and a rotatable vacuum anvil roll 128 to cutindividual strips 118 from the continuous side panel material 116. Thestrips 118 cut by a blade on the knife roll 126 can be maintained on theanvil roll 128 by vacuum and transferred to the transfer roll 124.

[0117] The rotatable transfer roll 124 can comprise a plurality ofrotatable vacuum pucks 130. The vacuum pucks 130 receive the strips 118of material 116 from the cutting assembly 122 and rotate and transferthe strips to the continuously moving bodyside liner material 104. Whenthe strips 118 are positioned as desired relative to the bodyside linermaterial 104, the strips are released from the pucks 130 byextinguishing the vacuum in the pucks. The pucks 130 can continue torotate toward the cutting assembly 122 to receive other strips. Asdisclosed by Van Gompel et al., the material 116 used to form the sidepanels can alternatively be provided in continuous form and pressurizedfluid-jets or a rotary die cutter can be employed to cut the material toform leg openings 52. Still alternatively, the side panels 34, 134 ofthe training pants 20 can be provided by portions of the bodyside liner42 and/or outer cover 40.

[0118] A continuous supply of material 140 used to form the outer cover40 can be provided from a supply roll 142 or other suitable source. Theouter cover material 140 can be transported over a laminator roll 144and bonded to the bodyside liner material 104. The absorbent assemblies114 are thereby sandwiched between the continuous materials 104 and 140.The inward portions of the strips 118 of side panel material 116 canalso be disposed between the bodyside liner material 104 and the outercover material 140. Alternative configurations for attaching the sidepanel material 116 are disclosed by Van Gompel et al. Various elementssuch as leg elastics 58 or waist elastics 54 and 56 can be bonded to theouter cover material 140 at an application station 146 prior to unitingthe bodyside liner and outer cover materials 104 and 140. Alternatively,leg elastics or waist elastics can be initially bonded to the bodysideliner material 104 or another material.

[0119] Bonding devices 148 such as ultrasonic bonders can be employeddownstream from the laminator roll 144 to bond the bodyside linermaterial 104, side panel material 116 and outer cover material 140. Forexample, these materials can be transported between a rotary ultrasonichorn and an anvil roll. Suitable rotary ultrasonic horns are describedin U.S. Pat. No. 5,110,403 to Ehlert, which is incorporated herein byreference. Such rotary ultrasonic horns generally have a diameter offrom about 5 to about 20 millimeters and a width of from about 2 toabout 15 millimeters. Alternatively, the ultrasonic horn may be astationary ultrasonic horn as is also known to those skilled in the art.Other suitable ultrasonic horns and ultrasonic bonders are commerciallyavailable from Branson Sonic Power Company, Danbury, Conn., U.S.A. Thebonding devices 148 could otherwise be a thermal or adhesive bonder asare well known.

[0120] The continuously moving product assemblage 113 next advances to afastener application station 150 where fastening components 82, 84 arebonded to the strips 118 of side panel material 116. The location of thefastening components 82, 84 on the composite is a function in part ofthe configuration of the assembly section 100. As shown in FIG. 4, theassembly section 100 of the illustrated embodiment is configured so thatthe upward facing surface of the product assemblage 113 will become theouter surface 30 of the training pants 20 and the downward facingsurface will become the inner surface 28. Moreover, the illustratedassembly section 100 is configured to produce partially assembledtraining pants 102 having the front waist region 22 of a leading garmentconnected to the back waist region 24 of a trailing garment. However, itis understood that the assembly section 100 could alternatively employany combination of different orientations. For example, the upwardfacing surface of the product assemblage 113 could form the innersurface 28 of the finished pants 20. Additionally or alternatively, theback waist region 24 of a leading pair of pants 102 can be connected tothe front waist region 22 of the trailing pair of pants, or the pantscan be arranged in a front-to-front/back-to-back relationship. Stillalternatively, the assembly section 100 could be constructed as across-machine direction process wherein the longitudinal axis 48 of eachpair of partially assembled pants 102 could be perpendicular to themachine direction 108 during part or all of the assembly process.

[0121] The locations of the fastening components 82, 84 in thisembodiment are best illustrated in FIG. 7, which shows a portion of theproduct assemblage 113 moving in the direction of arrow 108 immediatelyfollowing the fastener application station 150. Each individual strip118 of side panel material 116 defines a leading edge 152, a trailingedge 154, a distal edge 156 and an interior edge 158. A dashed line 159illustrates the location at which the product assemblage 113 cansubsequently be cut to provide the discrete partially assembled trainingpants 102. Based on the illustrated orientation of the continuouslymoving product assemblage 113, the first fastening components 82 can bebonded to the underside of the strips 118 and the second fasteningcomponents 84 can be bonded to the top of the strips. Additionally, thefirst fastening components 82 can be disposed relatively closer to thetrailing edge 154 and the second fastening components 84 can be disposedrelatively closer to the leading edge 152. The first fasteningcomponents 82 can be spaced in the machine direction 108 from the secondfastening components 84 so that the cut line 159 passes therebetween.

[0122] With reference again to FIG. 4, continuous webs of a secondfastener material 160 used to form the second fastening components 84can be provided from supply rolls 162 or other suitable sources. Thesecond fastener materials 160 can be cut into individual secondfasteners 84 by cutting assemblies 164 or other suitable devices. Theillustrated cutting assemblies 164 include rotatable knife rolls 166,rotatable vacuum anvil rolls 167, and rotatable backing rolls 168. Thecontinuous second fastener materials 160 can be cut by blades on theknife rolls 166, maintained on the anvil rolls 167 by vacuum, anddisposed on the top surfaces of the strips 118 of side panel material116.

[0123] Similarly, continuous webs of first fastener material 170 used toform the first fastening components 82 can be provided from supply rolls172 or other suitable sources. The first fastener materials 170 can becut into individual first fastening components by cutting assemblies 174or other suitable devices. The illustrated cutting assemblies 174include rotatable knife rolls 176, rotatable vacuum anvil rolls 177, androtatable backing rolls 178. The continuous first fastener materials 170can be cut by blades on the knife rolls 176, maintained on the anvilrolls 177 by vacuum, and disposed on the undersides of the strips 118 ofside panel material 116.

[0124] It is contemplated that other arrangements can be used to attachthe fastening components 82, 84 to the side panel material 116. Forexample, the fastening components 82, 84 can be applied to the sidepanel material 116 prior to uniting the side panel material with thebodyside liner material 104 and/or the outer cover material 140; thefastening components can be applied to the bodyside liner material 104and/or outer cover material 140, whether separate side panels 34, 134are used or not; portions of other elements such as the bodyside linerand/or outer cover can form one or more of the fastening components; theseparate side panels or integral side panels can themselves form one ormore of the fastening components; the fastening components 82, 84 can beattached as pre-engaged composites or the like without departing fromthe scope of this invention.

[0125] After the fastening components 82, 84 are disposed on the strips118 of side panel material 116, bonding devices 180 such as ultrasonicbonders can be employed to bond the fastening components to the strips.For example, the strips 118 can be transported between a rotaryultrasonic horn and an anvil roll, which devices are positioned on eachside of the process at the cross machine direction location of thefastening components 82 and 84. Alternately, the strips 118 may betransported using adhesive only. Particular ultrasonic bond patternscomprising individual, circular bonds which are compatible withmechanical fastening materials are disclosed in U.S. Pat. No. 5,660,666issued Aug. 26, 1997 to Dilnik et al., which is incorporated herein byreference. Efficient arrangements for attaching the fastening componentswith nonadhesive bonding devices are further described in U.S. patentapplication Ser. No. 09/855,484, filed on May 15, 2001 by J. D. Coenenet al. and titled “Methods For Making Garments With FasteningComponents,” which is incorporated herein by reference. For secureattachment, it may be desirable to attach the fastening components 82,84 to the side panel material 116 with both adhesive and thermal bonds.Suitable attachment adhesives are available from commercial vendors suchas Findley Adhesive, Inc., Wauwatosa, Wis., U.S.A.

[0126] In particular embodiments, the bonding devices 180 can providetimed, non-uniform bonding of the fastening components to the side panelmaterial 116. The degree of bonding, such as the number of bonds perunit area or the bond strength per unit area, can be greater in certaintarget areas compared to non-target areas. Enhanced bonding in targetareas can be beneficial particularly near the waist and leg openings 50and 52 to reduce delamination of the fastening components from the sidepanel material 116. Thus, the bonding devices 180 can be adapted tocreate relatively more bonds or stronger bonds between the fasteningcomponents 82, 84 and the side panel material 116 when the side panelmaterial 116 reaches a particular machine direction 108 location. In oneparticular embodiment, the target areas correspond to portions of thefastening components 82, 84 near the waist edges 38 and 39. The bondingdevices 180 can be registered to provide a relatively higher degree ofbonding which begins while disposed on one fastening component (such asthe fastening component 84 in FIG. 7), continues through the regionwhere the product assemblage 113 will subsequently be cut (see cut line159 in FIG. 7), and ends after being disposed on another fasteningcomponent (such as fastening component 82). Alternatively, the bondingdevices 180 can destroy engaging elements of the fastening components82, 84 in the target areas, so that the fastening components will beless able to aggressively attach to one another in the target areas.

[0127] The strips 118 of side panel material 116 can be trimmed ifdesired, for example to provide angled and/or curved leg end edges 70 inthe back waist region 24 (FIGS. 2 and 3). To this end, the assemblysection 100 can include a die cutting roll 182 and a backing roll 184.In the illustrated embodiment, a portion of each strip 118 is trimmedfrom the trailing edge 154 (FIG. 7) in order to form the angled and/orcurved leg end edges 70 in the back waist region 24.

[0128] The method and apparatus to this point provides a continuous webof interconnected and partially assembled training pants moving in themachine direction indicated by arrow 108. This continuously movingproduct assemblage 113 is passed through a cutter 186 which selectivelycuts the web into discrete, partially assembled training pants 102. Suchcutters 186 are generally known to those skilled in the art and caninclude, for example, the combination of a cutting roll 187 and an anvilroll 188 through which the web travels. The anvil roll 188 can include ahardened steel rotating roll while the cutting roll 187 can include oneor more flexible hardened steel blades clamped onto another rotatingroll. The pinching force between the blade on the cutting roll 187 andthe anvil roll 188 creates the cut. The cutting roll 187 can have one ormore blades depending upon the desired distance between the cuts. Thecutter 186 can further be configured to provide a spacing between theindividual cut pieces after they are cut. Such a spacing can be providedby transferring the cut pieces away from the cutter at a higher speedthan the speed at which the web is provided to the cutter.

[0129] In the manufacturing process shortly before the position of thecutter 186 is a first inspection location 189 shown schematically inFIG. 4. A first image capturing device (which could include multiplesuch devices) is located at the first inspection location so as tocapture an image of at least a portion of an individual training pant 20that has been substantially or fully completed prior to its beingfolded. The image capturing device provides an image of at least aportion of the partially assembled training pant 102 and, for example,the first fastening component 82, made of loop material, with thetraining pant positioned flat and lying on a conveyor as shown in FIG.4, and as shown schematically in FIG. 26. Image analyzing equipment,such as is well known in the art, including computer software andhardware (considered to be part of the first inspection location 189 asshown in FIG. 4) then determines the distance from a datum line 82 aindicated as position B (FIG. 26) placed on the loop material fasteningcomponent 82, to, for example, the adjacent outer most edge 82 b of theloop material fastening component 82 (the location of which is indicatedby A) and stores this information for future use, such as discussedbelow in connection with the second inspection location. The datum line82 a is established such that it will be visible by an image capturingdevice in a second inspection location discussed below and could be aline, a mark, an edge, or some other feature so long as it isdistinguishable by the image capturing device from other features of thearticle. In the case of the training pants example, the datum line 82 acan be in the form of a bond line formed by a thermal or ultrasonicanvil in the center of the loop material fastening component such thatit is distinctive from other bond patterns, if any, in the loopmaterial. This is what is depicted schematically in FIG. 26. Since sucha bond line essentially reduces the thickness of the loop material toalmost form a hole in it, the bond line will appear lighter to the imagecapturing device than the surrounding loop material and thus provides adistinctive visual image that can be distinguished from the surroundingmaterial by the image capturing device. Acceptable image capturingdevices for use in the first inspection location would include thosediscussed in more detail below for use in the second inspectionlocation. However, since the parts being inspected at the firstinspection station are all visible on the surface of the training pant,other image capturing devices, such as that disclosed in U.S. Pat. No.5,359,525 to Weyenberg, could be utilized.

[0130] With particular reference now to FIGS. 5, 8 and 9, the discretepartially assembled training pants 102 are delivered to and folded atthe folding section 200 using any suitable folding mechanism 202. Forexample, the partially assembled training pants 102 can be folded abouta fold line which generally bisects the training pants laterally throughthe crotch region 26. As such, the waist regions 22 and 24 of thepartially assembled pants 102 are positioned in opposed relationshipwith each other, with the side panels 34, 134 extending laterallyoutward therefrom parallel to the transverse axis 49 of the trainingpants in opposed relationship with each other. Desirably, each of thetraining pants 102 is consistently folded about the fold line such thatthe front and back waist edges 38 and 39 of the training pants alignwith each other.

[0131] A variety of folding mechanisms 202 can be used, such as bladefolders, linear folders, book folders, tucker blades or the like. Thespecific type selected for a given application may depend upon the typeof garment being manufactured and the type of fastening mechanism usedto secure the garment in a pants configuration. In the illustratedembodiment, the folding mechanism 202 controls the side panels 34, 134during folding so that the refastenable fastening components 82, 84 areinhibited against engaging one another or engaging another materialduring the folding operation. Other arrangements for maintainingseparation of the side panels 34, 134 and fastening components 82, 84during folding are disclosed in U.S. patent application Ser. No. ______unknown, filed on May 15, 2001 by J. D. Coenen et al. and titled“Folding And Manufacture Of Pants,” which is incorporated herein byreference.

[0132] The illustrated blade folding mechanism 202 comprises a pluralityof rotating folding or tucker blades 240 (FIG. 9) which are configuredto contact the training pants 102 along the fold line. Rotation of thefolding blades 240 can force the training pants 102 into a nip 204 (FIG.8) between two rotating folding conveyors 206 and 208 causing thetraining pants to fold about the fold line. The folding conveyors 206and 208 can form part of a transport system for moving the foldedtraining pants 102 in the machine direction 108 (FIG. 8). The foldedtraining pants 102 are illustrated as being transported in the machinedirection 108 with the crotch region 26 leading the waist regions 22 and24. Alternatively, the process and apparatus could be modified so thatthe waist regions lead the crotch region (not shown).

[0133] The series of unfolded, discrete training pants 102 can betransferred from the vacuum anvil roll 188 (FIGS. 4 and 5) of the cutter186 to the upper folding conveyor 206 (FIGS. 5, 8 and 9). The trainingpants 102 can be held by vacuum on the upper folding conveyor 206 andtransported toward the nip 204 formed between the folding conveyors 206and 208. While being transported toward the nip 204, the side panels 34,134 can be smoothed out or straightened if desired by various meansincluding fluid stabilizing devices. For example, air knives 215 (FIG.8), air bars, air nozzles or the like can be mounted in proximity to theupper folding conveyor to provide a stream of fluid directed toward theside panels to stabilize and/or straighten the side panels. The airknives 215 can blow the side panels 34, 134 against skid plates 216positioned transversely outward from the upper folding conveyor belt212. Alternatively, or in addition thereto, the upper folding conveyor206 can incorporate fluid stabilizing devices (not shown) consisting offluid manifolds operatively connected to a high pressure fluid source tofluidly shake the side panels 34, 134. The fluid stabilizing devices(not shown) desirably prevent folding of the side panels 34, 134 as thetraining pants 102 move along the upper folding conveyor 206. Sensingdevices can also be employed at this point to detect products that havefolded side panels or that are misaligned relative to the machine centerline.

[0134] The product folding nip 204 can be formed between a timed vacuumnose roll 218 of the upper folding conveyor 206 and a timed vacuum noseroll 219 of the lower folding conveyor 208 (FIGS. 5 and 8). As theleading edge of each pair of pants 102 is introduced onto the upper noseroll 218, a rotary valve 221 can be used to negate vacuum draw of thenose roll. This allows the leading edge of the pants 102 to pass by thenose roll 218 without getting sucked into the nip 204. Alternatively ofcourse, the vacuum source can be temporarily disconnected from the noseroll 218. Any suitable control system can be used to repeatedly activateand deactivate vacuum operation of the nose rolls 218 and 219. Inparticular embodiments, compressed air nozzles or jets (not shown) canbe employed to cycle vacuum to the nose rolls 218 and 219. This is doneby injecting compressed air inside the nose roll 218 and 219 internalchambers to negate the vacuum employed to cycle vacuum to the nose rolls218 and 219.

[0135] A product control drum 220 can guide the leading half of thetraining pant 102 onto a transfer plate 222 (FIGS. 5 and 8). The productcontrol drum 220 can comprise a plurality of vacuum pucks 224 whichrotate in the direction of arrow 225. The illustrated product controldrum 220 includes four vacuum pucks 224 to guide four training pants 102per revolution. Rotation of the product control drum 220 can be timed sothat a vacuum puck 224 grabs the leading half of a training pants 102and transfers the leading edge onto the transfer plate 222. Theabsorbent chassis 32 and/or side panels 134 of the leading half can becarried on a vacuum puck 224 past the nose roll 219 of the lower foldingconveyor 208. Compressed air can be introduced inside this lower noseroll 219 at this point to negate vacuum draw and to permit the entireleading edge and side panels 134 to transfer onto the transfer plate222. Alternatively of course, the vacuum source can be temporarilydisconnected from the nose roll 219.

[0136] With reference to FIG. 9, the opposed tucker blades 240 move inan orbital manner to pass through the vertical path of the trainingpants 102. The tucker blades 240 can contact the crotch region 26 of thepants 102 and insert the crotch region into the folding nip 204 (FIG.8). As this happens, the leading half of the pants 102 reversesdirection over the transfer plate 222 and is pulled into the nip 204.The vacuum puck 224 can cease drawing vacuum at this point to releasethe leading half. Correspondingly, the trailing half of the pants 102 ispulled around the upper nose roll 218. Thus, both halves of the trainingpants 102 can change from motion in a generally vertical plane to motionbetween the folding conveyors 206 and 208 in a generally horizontalplane.

[0137] The illustrated folding mechanism 202 can maintain separationbetween the front and back side panels 34, 134. As the pants 102 enterthe folding nip 204, compressed air can be shut off to the upper noseroll 218 so that the side panels 34 of the trailing half are drawn byvacuum to the upper nose roll. The trailing side panels 34 are thusdrawn to the upper nose roll 218 and follow its rotation around the rolland over side panel separation plates 230 (FIGS. 8 and 10). Similarly,as the leading half of the pants 102 is pulled into the folding nip 204,compressed air can be shut off to the lower nose roll 219 so that theside panels 134 of the leading half are drawn by vacuum to the lowernose roll. The leading side panels 134 are thus drawn to the lower noseroll 219 and follow its rotation around the roll and beneath the sidepanel separation plates 230.

[0138]FIG. 10 illustrates a portion of partially assembled trainingpants 102 positioned between the upper and lower folding conveyors 206and 208 at a location downstream from the nose rolls 218 and 219. Atthis point, the training pants 102 have been folded in half andtransported in the machine direction 108 (FIG. 8) by the conveyors 206and 208. The illustrated folding mechanism 202 can thus maintain thefront side panels 34 separated from the back side panels 134 duringfolding.

[0139] Each folding conveyor 206 and 208 as illustrated in greaterdetail in FIG. 10 can comprise a frame structure 210, a plurality ofrotatable pulleys 211 associated with the frame structure, and acontinuous belt 212 carried on the pulleys. A drive system and conveyorshaft (not shown) can be used to rotatively drive one or more of thepulleys. The folding conveyors 206 and 208 can comprise vacuum conveyorsas are well known in the art, in which case the continuous belt can beformed of a fluid permeable material. The folding conveyors desirablytransport the training pants 102 with the longitudinal center line ofthe pants traveling on the longitudinal center line of the conveyors. Asdepicted, the front and back side panels 34, 134 can project laterallyoutward from the frame structure 210, outstretched in the cross-machinedirection.

[0140] While traveling on the folding conveyors 206 and 208, the sidepanels 34, 134 can be smoothed out or straightened if desired by variousmeans including fluid stabilizing devices (not shown). It is possible,if desired, to provide fluid streams such as from air bars 215 to guidethe side panels 34, 134 outward from the upper folding conveyor 206,upstream of the folding nip 204. In addition, it is possible, ifdesired, to provide fluid streams such as from air bars 217 to continueguiding and controlling the side panels 134 of the leading half of theproduct 102, while over the transfer plate 222 downstream of the foldingnip 204. The air bars 215 and 217 can be located adjacent the outboardedges of conveyors 206 and 208, directing air generally towards the sidepanels 34, 134 of training pant 102 and generally away from the edges ofthe conveyors. The air bars 215 and 217 can additionally be displacedfrom the planes of the conveyors 206, 208 so that the training pant 102can pass between the air bars and the conveyors. Suitable fluidstabilizing devices can comprise air knives, air bars, air nozzles,vacuum devices or the like to provide a stream of fluid directed towardthe side panels. The fluid stabilizing devices can be incorporatedwithin either or both of the folding conveyors 206 and 208 or cancomprise separate devices positioned in proximity to the conveyors.

[0141] Following conveyance of the partially assembled training pants102 through the illustrated folding mechanism 202, the front waistregion 22 and front side panels 34 of the partially assembled trainingpants as shown in FIG. 10 are disposed above the back waist region 24and back side panels 134. The fastening components 82 are disposed onthe inner surface 28 of the back side panels 134 and the fasteningcomponents 84 are disposed on the outer surface 30 of the front sidepanels 34. The separation plates 230 can extend in the machine direction108 to maintain separation between the front and back side panels 34,134. The separation plates 230 can comprise a low friction material orcoating, such as: stainless steel; Teflon®; aluminum; ultra-highmolecular weight polyethylene (UHMW-PE); polyoxymethylene (acetals), forinstance a homopolymer available from E. I. Du Pont de Nemours andCompany, Wilmington, Del., USA under the tradename DELRIN; or the like.In particular embodiments, the separation plates 230 can comprise a thinlayer of Teflon®, UHMW-PE, DELRIN or the like glued to a plate formed ofsteel, aluminum or the like. The separation plates 230 can be mountedusing suitable support members 232 (FIG. 10) to either the foldingconveyors 206 or 208 or other suitable frame structure (not shown).Alternately, the panel separation plates 230 can have air stabilizationcomponents (not shown). A fluid surface may also be used to separate theside panels 34, 134.

[0142] From the folding station 200, the continuous stream of discrete,partially assembled and folded training pants 102 enters a seamingsection 250 (FIG. 6) and is transported therethrough in a machinedirection 108 indicated by the direction arrow in FIG. 6. In general,the seaming section 250 controls the unattached side panels 34, 134 soas to position portions of the side panels, and more particularly therespective fastening components 84, 82 of the side panels, in at leastpartially opposed relationship with each other; to connect the fasteningcomponents together to define the engagement seams 88; and to thenexpand the side panels at the engagement seam and inspect the engagementseams 88 to assess whether the side panels are properly aligned andconnected. The seaming section 250 thus converts the discrete, partiallyassembled and folded training pants 102 into the pre-fastened trainingpants 20 (FIG. 1) having the waist opening 50, leg openings 52 and theinterior space 51 bounded in part by the engagement seams 88.

[0143] Construction and operation of the seaming section 250 is furtherdescribed herein with particular reference to FIGS. 11-21 and 24. FIGS.11 and 12 respectively illustrate side elevations of the upstream anddownstream portions of the seaming section 250, FIG. 13 illustrates atop plan of a lower portion of the seaming section and FIG. 24illustrates an end view of a downstream end of the seaming section.FIGS. 14-21 are sections taken at sequential locations along the seamingsection 250. For ease of explanation, these sections illustrate only oneside (e.g., the right hand side relative to the machine direction 108)of the seaming section 250 and the training pants 102 conveyedtherethrough, it being understood that the left hand side of the seamingsection is constructed and operates substantially similar to the righthand side.

[0144] With particular reference to FIGS. 6, 11 and 14, the seamingsection 250 comprises upper and lower alignment conveyors, generallyindicated as 256 and 258, respectively, which broadly define a transportsystem for transporting discrete, partially assembled training pants 102from the upper and lower folding conveyors 206 and 208 (FIG. 5) throughthe seaming section in the machine direction 108. More specifically, thealignment conveyors 256 and 258 define therebetween a pant transportplane, which in the illustrated embodiment is generally horizontal, inwhich the training pants 102 are transported through the seaming section250. As illustrated, the upper alignment conveyor 256 comprises framestructure 260, one or more vacuum chambers 262 (FIG. 14) defined withinthe frame structure, one or more vacuum cover plates 264 (FIG. 14)mounted on the frame structure and one or more continuousfluid-permeable belts 266 carried on a plurality of rotatable pulleys268 or other suitable devices. Similarly, the lower alignment conveyor258 comprises frame structure 270, a vacuum chamber 272 (FIG. 14)defined within the frame structure, a vacuum cover plate 274 (FIG. 14)mounted on the frame structure and a continuous fluid-permeable belt 276carried on a plurality of rotatable pulleys 278 or other suitabledevices. The vacuum cover plates 264 and 274 and related equipment canbe adjustable if desired to accommodate various pants sizes. A drivesystem (not shown) and conveyor shaft (not shown) can be used torotatively drive one or more of the pulleys 268 and 278. The vacuumchambers 262 and 272 can be operatively connected to a source of vacuum(not shown) and the vacuum cover plates 264 and 274 can be provided witha plurality of holes 269 and 279, respectively.

[0145] With reference to FIG. 14, the seaming section 250 is alsoillustrated and described herein with the training pants 102 orientedsuch that the front waist region 22 is drawn against the upper alignmentconveyor 256 and the back waist region 24 is drawn against the loweralignment conveyor 258. Thus, the front side panels 34 are initiallypositioned above the back side panels 134, with the fastening component84 of the front side panel facing up (e.g., away from the fasteningcomponent 82 of the back side panel). However, it is understood that thepants 102 may be inverted, e.g., such that the back waist region 24 isdrawn against the upper alignment conveyor 256 while passing through theseaming section 250, without departing from the scope of this invention.Also, while the seaming section 250 of the illustrated embodimentassembles pre-fastened training pants 20 with the back side panel 134overlapping the front side panel 34 as shown in FIG. 1, it is understoodthat the seaming section 250 could be configured so that the front sidepanel overlaps the back side panel after passing through the seamingsection.

[0146] The upper alignment conveyor 256 of the illustrated embodimenthas an operative width sufficient to draw the full width of the frontwaist region 22 and front side panels 34 of the training pants 102against the upper conveyor belt 266 as shown in FIG. 14 fully orpartially along the length of the seaming section 250. The loweralignment conveyor 258 is relatively narrow compared to the upperalignment conveyor 256 and has a width, for example, approximately equalto the width of the absorbent chassis 32 thereof. This permits the backside panels 134 to extend laterally out beyond the lower alignmentconveyor 258. As another example, the width of the lower alignmentconveyor 258 may generally correspond to the distance between the seams66 (FIG. 2) along which the side panels 34 and 134 are bonded to theabsorbent chassis 32.

[0147] The respective vacuum pressures acting on the upper and loweralignment conveyors 256, 258 are preferably sufficient to draw andretain the waist regions 22 and 24 of the training pants 102 against therespective conveyors to inhibit pinching of the waist regions betweenthe conveyors. Vacuum control of the waist regions 22, 24 also inhibitslateral movement of the absorbent chassis 32 to thereby improvepositioning and alignment of the side panels 34, 134. As an example, theupper alignment conveyor 256 can operate over a range of vacuumpressures, such as about 1 to about 30 inches of water or greater belowatmospheric pressure. The lower alignment conveyor 258 can also operateover a range of vacuum pressures, such as in the range of about 1 toabout 30 inches of water or greater below atmospheric pressure. Suitableconveyor mechanisms such as vacuum conveyors or non-vacuum conveyors areknown in the art and available from various commercial vendors and thuswill not be further described herein except to the extent necessary toset forth the present invention.

[0148] Referring to FIGS. 6 and 11-13, the seaming section 250 furthercomprises side panel positioning devices, generally indicated at 330,for vertically and laterally positioning the back side panels 134relative to the front side panels 34; side panel transfer devices,generally indicated at 430, for moving the respective fasteningcomponents 84, 82 of the side panels 34, 134 into engagement with eachother to define the engagement seams 88; and inspection systems 530(generally shown in FIG. 24) for inspecting the engagement seams 88following engagement of the fastening components.

[0149] The positioning devices 330 of the illustrated embodiment aremounted on opposite sides of the lower alignment conveyor 258 as shownin FIG. 13, although it is understood that the positioning devices mayinstead be mounted on the upper alignment conveyor 256 or other suitableframe structure of the seaming section 250. Each positioning device 330comprises an elongate tubular member 332 extending generally in themachine direction 108 from an upstream end (FIGS. 6, 11) 334 adjacent anupstream end of the seaming section 250 to a downstream end 336. Thetubular member 332 of the illustrated embodiment comprises opposed walls344, 346 (FIG. 14) together defining a generally L-shaped cross-sectionof the tubular member and an internal flow chamber 340 extendinglongitudinally therethrough. A slot 342 (FIG. 14) is formed in thetubular member 332 in fluid communication with the internal flow chamber340 and extends longitudinally substantially the length of the tubularmember. The slot 342 faces laterally inward toward the lower alignmentconveyor 258 for receiving the back side panel 134 into the internalflow chamber 340 (FIG. 14). The walls 344, 346 of the tubular member 332may be formed separately and secured together by suitable methods, orthey may be formed integrally. It is also understood that the tubularmember 332 and internal flow chamber 340 may be other than L-shaped incross-section without departing from the scope of this invention.

[0150] The tubular member 332 can be formed of any suitable material.For example, portions or surfaces of the tubular member 332 which maycome into contact with the training pants 102 are desirably formed of alow friction material. Suitable low friction materials or coatingsinclude but are not limited to: stainless steel; low carbon steel;polycarbonate material; Teflon®; aluminum; ultra-high molecular weightpolyethylene (UHMW-PE); polyoxymethylene (acetals), for instance ahomopolymer available from E. I. Du Pont de Nemours and Company,Wilmington, Del. USA under the tradename DELRIN; or the like.

[0151] The flow chamber 340 of the tubular member 332 is in fluidcommunication with a source of vacuum V via suitable vacuum hoses 350(FIGS. 6, 11, 13) for drawing fluid, such as air, into the flow chambervia the slot 342 formed in the tubular member such that the fluid flowsgenerally laterally outward within the flow chamber as indicated by thedirection arrow in FIG. 14. The vacuum pressure within the flow chamber340 can vary, for example, from about 1 to about 10 inches of water orgreater below atmospheric pressure, and more particularly from about 2to about 8 inches of water below atmospheric pressure. It is alsocontemplated that instead of or in addition to the vacuum pressure,pressurized fluid (not shown) can be directed into the internal chamber340 via the slot 342 to establish the fluid flow laterally outwardwithin the internal chamber.

[0152] The fluid flow within the internal flow chamber 340 is sufficientto draw the back side panel 134 laterally outward relative to themachine center line, and desirably at least partially into the flowchamber, to thereby promote straightening of the back side panel. Theslot 342 and the flow chamber 340 are thus desirably sized toaccommodate the back side panel 134 and fluid flow therethrough. Forexample, the slot 342 desirably has a width of about 5 millimeters toabout 20 millimeters, and more desirably about 10 millimeters to about15 millimeters. The walls 344, 346 of the tubular member 332 canconverge or diverge relative to one another, or be generally parallel asillustrated. The depth of the flow chamber 340 generally depends uponthe application and the amount of back side panel 134 material to bereceived therein. For example, the internal flow chamber 340 may have adepth of about 5 to about 20 millimeters. As seen best in FIGS. 14 and15, the tubular member 332 of each positioning device 330 is positionedlower than the lower alignment conveyor 258 so that when the back sidepanel 134 is drawn into the flow chamber 340, the back side panelextends laterally outward and down from the back waist region 24 beingheld against the conveyor.

[0153] Now referring to FIGS. 6, 11, 13 and 16-18, the side paneltransfer devices 430 comprise vacuum conveyors spaced laterally outwardof the lower alignment conveyor 258 a distance generally correspondingto the lateral positions of the fastening components 82 of the back sidepanels 134 as the panels exit the downstream end 336 of the positioningdevices 330. More particularly, each side panel transfer device 430comprises suitable frame structure 432, rotatable pulleys 434 (FIGS. 6and 11) associated with the frame structure, a vacuum chamber 436 (FIGS.16-18) defined within the frame structure, a vacuum cover plate 438(FIGS. 16-18) mounted on the frame structure, and a continuous belt 440carried by the pulleys. A drive mechanism (not shown) and correspondingconveyor shaft (not shown) can be used to rotatively drive one or moreof the pulleys 434. The side panel transfer devices 430 can be alignedparallel to the machine direction 108 as shown in FIG. 13 or cantedinward or outward, for example, to improve side panel 34, 134 alignmentwith the machine direction.

[0154] Each side panel transfer device 430 angles up toward the pantstransport plane defined by the upper and lower alignment conveyors 256,258 as the device extends in the machine direction 108 from an upstreamend 442 disposed slightly upstream and below the downstream end 336 ofthe positioning device 330, to a downstream end 444 disposed in closelyspaced relationship with the upper alignment conveyor 256. The sidepanel transfer device 430 and the upper alignment conveyor 256 thusdefine a nip therebetween at the downstream end of the device, thepurpose of which will become apparent.

[0155] The side panel transfer device 430 can alternatively compriseother devices (not shown) for sequentially or simultaneously effectingupward movement of the laterally outward portion of the back side panel134. By way of illustration, suitable side panel transfer devices 430can alternatively comprise disks or wheels, either aligned in themachine direction 108 or canted and/or tilted relative thereto so thatthe disks or wheels raise the side panels and nip the fastenerstogether. Suitable wheel devices can, but need not, be timed ellipticalwheels, and can comprise vacuum or traction surface wheels or the like.Still alternatively, the side panel transfer devices 430 can comprise4-bar linkage mechanisms carrying a panel engagement head which contactsthe back side panel 134 to raise the panel relative to the plane of thelower alignment conveyor 258. The rotary motion provided by the 4-barlinkage can allow the panel engagement head to raise a back side panel134 relative to the lower alignment conveyor 258, with the back sidepanel being allowed to slip off the inward edge of the panel engagementhead. A drive mechanism for the 4-bar linkage can be programmed to varythe angular velocity of the panel-engagement head such that its velocityin the machine direction 108 matches the speed of the back side panel134 while the panel-engagement head is in contact with the back sidepanel. Alternatively, the angular velocity of the panel-engagement headcan be matched with the velocity of the side panel using a cam gearbox,non-circular gearing, or the like. Such devices could further comprise afeedback system to register the panel-engagement head to the back sidepanel 134. In yet another alternative embodiment, the side paneltransfer devices 430 can comprise folding boards or folding skis toprovide sequential or simultaneous inward and upward relative movementof the laterally outward portions of the back side panels 134 and thefastening components 82.

[0156] Now referring to FIGS. 12, 13 and 17-23, the second inspectionlocation comprises an inspection system 520 which includes a supportassembly, generally indicated at 530, for supporting the front and backside panels 34, 134 in a generally expanded configuration to facilitateinspection of the engagement seam 88. The support assembly 530 comprisesa rectangular plate 532 (FIGS. 17 and 22) mounted on the side paneltransfer device 430 by a suitable mounting member 534 (FIG. 17) andfasteners 536. The rectangular plate 532 is oriented generally parallelto the pants transport plane defined by the upper and lower alignmentconveyors 256, 258 (e.g., generally horizontal in the illustratedembodiment). A leading edge 538 (FIG. 13) of the plate 532 is disposedjust downstream from the upstream end 442 of the transfer device 430.Rectangular plate 532 terminates at a trailing edge 540 upstream of thedownstream end 444 of the transfer device 430. As best seen in FIG. 17,the rectangular plate 532 also extends laterally inward toward themachine center line above the transfer device 430 (and hence above theback side panel 134 supported by the transfer device) to separate thefastening components 82, 84.

[0157] An elongate bar 542 overlies an inner edge margin 544 of therectangular plate 532 and is connected to the upper surface of therectangular plate 532 as shown in FIGS. 17 and 23, such as by welding orsuitable fasteners (not shown). The bar 542 extends in the machinedirection 108 downstream beyond the trailing edge 540 of the plate 532to a downstream end 546 (FIGS. 13, 23) of the bar. The bar 542 has achannel 545 formed in the outer side thereof and extending downstreamfrom the trailing edge 540 of the rectangular plate 532 to thedownstream end 546 of the bar. As an example, the bar 542 of theillustrated embodiment has a width of about 0.375 inches and a height ofabout 0.375 inches. It is understood, however, that the cross-sectionaldimensions of the bar 542 may be larger or smaller, and that thecross-section of the bar may be circular, I-shaped, T-shaped or othersuitable shape without departing from the scope of this invention.

[0158] The bar 542 is disposed higher than the lower alignment conveyor258 for positioning within the interior space 51 of the pants 102between the front and back side panels 34, 134 upon conveyance of thetraining pants in the machine direction 108 over the bar. The bar 542 isalso positioned laterally between the lower alignment conveyor 258 andthe side panel transfer device 430 for interposition between theabsorbent chassis 32 and the engagement seam 88 following connection ofthe fastening components 82, 84 as shown in FIG. 18 and described laterherein. As best seen in FIGS. 18-21, a cable 547 extends longitudinallywithin the channel 545 and is in electrical communication with aninspection system control (not shown) which controls operation of theinspection system 520 to inspect the engagement seam 88. An elongatechannel cover 549 having a generally L-shaped cross-section is securedto the bar 542 by suitable fasteners (not shown) to cover the channel545 formed therein to thereby enclose the cable within the channel.However, it is contemplated that the bar 542 may instead be of unitaryconstruction and have a passage extending longitudinally therethroughfor receiving the cable.

[0159] With particular reference to FIGS. 13, 22 and 23 an elongatesupport member 548 is mounted on the bar 542 generally at the downstreamend 546 thereof and has an upstream end 550 spaced longitudinally (e.g.,in the machine direction 108) from the downstream end 444 of the sidepanel transfer device 430. More particularly, the support member 548comprises a top wall 552 having an inner edge margin 554 (FIG. 20) whichoverlies the bar 542 and is secured thereto by suitable fasteners (notshown). The top wall 552 of the support member 548 extends laterally outfrom the bar 542 generally parallel to the pants transport plane definedby the upper and lower alignment conveyors 256, 258 (which in theillustrated embodiment is horizontal).

[0160] An outer side wall 556 (FIGS. 20, 22) is secured to the outeredge of the top wall 552, such as by being formed integrally therewith,to define an upper corner 558 of the support member 548 and depends fromthe top wall generally inward at an angle relative thereto. Thecross-section of the support member 548 is thus generally V-shaped, andis more particularly the shape of the numeral “7”. As an example, theouter side wall 556 desirably forms an angle with the top wall 552 inthe range of about 0 degrees to about 180 degrees. A bottom wall 560 issecured to the lower edge of the side wall 556, such as by being formedintegrally therewith, to define a lower corner 562 of the support member548 and extends generally inward and up from the side wall toward thelower alignment conveyor 258. However, it is contemplated that thebottom wall 548 may be omitted without departing from the scope of thisinvention. As shown in FIG. 20, the upper and lower corners 558, 562 ofthe support member 548 are desirably rounded to inhibit tearing of thefront and back side panels 34, 134 as the side panels are conveyed overthe support member.

[0161] As best seen in FIGS. 6, 12 and 13, the support member 548 has atapered lead portion 564 which gradually increases in cross-sectionaldimension as the support member extends from its upstream end 550 wherethe cross-sectional dimension of the support member correspondsgenerally to that of the bar 542 to a main portion 566 of the supportmember along which its cross-sectional dimension is generally uniform.As an example, the main portion 566 of the support member 548 of theillustrated embodiment has a width of about 1.33 inches and a height ofabout 2 inches. As an additional example, the support member 548 isapproximately 15.25 inches in length, with the lead portion 564 beingabout 5.5 inches long and the main portion 566 being about 9.75 incheslong.

[0162] The support member further comprises an inner side wall 563(FIGS. 21-23) which extends between the top wall 552 and the bottom wall560 in generally parallel spaced relationship with the outer side wall556 along the length of the main portion 566 of the support member 548to define a channel 565 therebetween. For example, the support memberchannel 565 of the illustrated embodiment is approximately 0.5 incheswide. An upper portion 567 of the inner side wall 563 extends laterallybeneath the top wall 552 of the support member 548 to between the topwall and the support assembly bar 542 such that the inner side wall issecured to the bar by the same fasteners (not shown) which secure thetop wall to the bar.

[0163] The support member 548 is supported by the bar 542 forpositioning within the interior space 51 of the training pants 102generally vertically between the portions of the front and back sidepanels 34, 134 extending on opposite sides of the engagement seam 88 asthe pants are conveyed in the machine direction 108 over the supportmember. The lower corner 562 of the support member 548 along the mainportion 566 thereof is disposed substantially below the lower alignmentconveyor 258 (and hence below the back waist region 24 of the absorbentchassis 32). The support member 548 is also supported for positioninglaterally out from the lower alignment conveyor 258, between theabsorbent chassis 32 and the engagement seam 88. It is contemplated thatthe vertical and/or lateral position of the support member 548 relativeto the lower alignment conveyor 258 may vary to adjust the positioningand relative expansion of the side panels 34, 134 as the pants 102 areconveyed over the support member in the manner to be described. However,the lateral spacing of the support member 548 from the lower alignmentconveyor 258 is desirably sufficient to inhibit pinching or binding ofthe back side panel 134 therebetween.

[0164] In the illustrated embodiment, the inspection system 520 alsocomprises an air bar (broadly, a fluid delivery device), generallyindicated at 570 (FIGS. 6, 12 and 21), extending longitudinally inparallel spaced relationship with the main portion 566 of the supportmember 548 at a position which is generally lower than and laterallyoutward of the lower corner 562 of the support member. The air bar 570comprises an elongate, cylindrical tube 572 in fluid communication witha source (not shown) of pressurized fluid, such as air, for receivingpressurized air within an internal passage 574 (FIG. 21) of the tube.Exhaust openings 576 (one of which is shown in FIG. 21) are formed inthe side wall of the tube 572 in longitudinally spaced relationship witheach other along the length of the tube. The exhaust openings arelocated on an upward and slightly inward facing portion of the side wallto direct pressurized fluid exhausted from the tube toward the outerside wall 556 of the support member 548 for impacting at least one ofthe front and back side panels 34, 134 at the engagement seam 88 tothereby urge the engagement seam 88 to lie generally flat on the outerside wall 556 of the support member 548.

[0165] As an example, the air bar 570 of the illustrated embodiment hasa length of about 9.75 inches, an internal diameter of about 0.5 inchesand exhaust openings 576 each having a diameter of about 0.05 inches andspaced about 1 inch apart along the length of the air bar. Pressurizedfluid received by the air bar 570 and exhausted therefrom toward theside wall 556 of the support member 548 is desirably in the range ofabout 10 psi to about 40 psi. It is understood that the air bar 570 maybe positioned other than below and outward of the lower corner 562 ofthe support member 548, as long as pressurized fluid exhausted from theair bar is directed generally inward toward the side wall 556 of thesupport member. It is also contemplated that the air bar 570 may beomitted without departing from the scope of this invention.

[0166] The inspection system 520 further comprises a radiation source,generally indicated at 582 in FIGS. 21-23, disposed within the supportmember channel 565 formed by the inner and outer side walls 563, 556 ofthe support member 548 for positioning within the interior space 51 ofthe pants 102 as the pants are conveyed in the machine direction 108over the support member 548. The radiation source 582 of the illustratedembodiment is an infrared radiation source capable of emitting radiationin the near infrared/infrared spectrum (i.e., radiation having awavelength between about 700 nanometers and one millimeter). Moredesirably, the infrared radiation source 582 emits radiation in therange of about 700 to about 1200 nanometers. As an example, theradiation source 582 shown in FIGS. 21-23 comprises an array of infraredLED's 584 mounted on a circuit board 586. The LED's 584 are each 3-5 mmin length and capable of emitting infrared radiation at a wavelength ofabout 940 nanometers. As an additional example, the radiation source 582of the illustrated embodiment is about 8.52 inches long, about 1.71inches wide and comprises about 432 infrared LED's. One such radiationsource 582 is available from RVSI of Weare, N.H., U.S.A. as part number010-904504.

[0167] It is contemplated that certain zones (not shown) of theradiation source 582 may emit radiation at a different intensity levelor wavelength than other zones. For example, with reference to theradiation source 582 illustrated in FIG. 23, one or more groupings ofthe LED's 584, such as those disposed generally toward the longitudinalends of the radiation source, may generate infrared radiation at a lowerintensity level than the remaining LED's disposed longitudinally centralof the radiation source. Various configurations and operation of aradiation source 582 having multiple zones of varying radiationintensity are described in co-assigned U.S. application entitled (KCC4840) “Apparatus and Method for Making and Inspecting Pre-FastenedArticles”, U.S. Ser. No. ______, which is incorporated herein byreference. It is also understood that the radiation source 582 foremitting infrared radiation may instead comprise mercury vapor lamps,argon lamps, arc lamps, lasers and other suitable radiation emittingdevices without departing from the scope of this invention. Also, theradiation source 582 may instead, or may additionally, emit visibleand/or ultraviolet radiation. For example, one such radiation source isa fiber optic light source which emits radiation in the range of about400 to about 700 nanometers using a tungsten or halogen bulb and isavailable from E.G. & G. of Salem, Mass., U.S.A.

[0168] The radiation source 582 is in electrical communication with theinspection system control via the cable 547 and may be operated by thecontrol to emit radiation either intermittently or continuously. Forexample, the inspection system control may operate the radiation source582 to emit radiation therefrom intermittently in response to theengagement seam 88 of the training pants 102 being conveyed in themachine direction 108 over the support member 548.

[0169] Referring particularly to FIG. 23, the support member 548,including the top wall 552, the inner and outer side walls 563, 556 andthe bottom wall 560 are generally constructed of metal, and moredesirably steel. However, a rectangular portion of the outer side wall556 of the support member 548 is constructed of a material which permitsthe transmission therethrough of radiation emitted by the radiationsource 582. More particularly, the outer side wall 556 partiallycomprises a diffuser plate 588 constructed of a material which diffusesradiation emitted by the radiation source 582 as radiation istransmitted out through the diffuser plate. The diffuser plate 588 ofthe illustrated embodiment is generally rectangular and is received in arectangular opening 590 of the outer side wall 556 in generally flushalignment therewith. The thickness of the diffuser plate 588 isdesirably in the range of about 0.125 inches to about 0.375 inches.However, it is understood that the material from which the diffuserplate 588 is constructed, as well as the thickness of the diffuserplate, may vary depending on the radiation source 582 and the desireddiffusion of radiation emitted by the radiation source. As an example,the illustrated diffuser plate 588 for diffusing infrared radiationemitted by the radiation source 582 is approximately 9.75 inches long,1.94 inches wide and has a thickness of about 0.125 inches. One suitablematerial from which the diffuser plate 588 may be constructed isavailable from Quadrant Engineering Plastics of Reading, Pa., U.S.A.under the tradename ACETRON® GP.

[0170] An insulating sheet 592 (FIG. 23) constructed of an electricallyinsulating material is positioned between the circuit board 586 of theradiation source 582 and the inner side wall 563 of the support member548 to electrically isolate the radiation source from the supportmember. For example, the insulating sheet 592 of the illustratedembodiment is constructed of plastic and has a thickness of about 0.008inches.

[0171] An image capturing device, generally indicated at 594 (FIGS. 13and 24), of the inspection system 520 at the second inspection locationis mounted on suitable frame structure 596 for positioning exterior ofthe training pants 102 as the pants are conveyed in the machinedirection 108 over the support member 548 and radiation source 582. Inthe illustrated embodiment, the image capturing device 594 is mounted onthe frame structure 596 by an adjustable mounting assembly, generallyindicated at 598, to permit selective adjustment of the device positionand orientation relative to the support member 548, such as in themachine direction and in the cross-machine direction. However, it isunderstood that the image capturing device 594 may instead be secured tothe frame structure 596 against movement relative to the support member548 without departing from the scope of this invention.

[0172] The image capturing device 594 of the illustrated embodiment isaimed generally toward the support member 548, and is more particularlyaimed toward the outer side wall 556 of the support member along a sightline (not shown) which is generally perpendicular to the outer sidewall. The device 594 is desirably operable to detect infrared radiationtransmitted by the radiation source 582 through the diffuser plate 588and the front and back side panels 34,134 at the engagement seam 88 andto produce a two-dimensional image of the engagement seam. As a result,the captured image will include variations therein which correspond tovariations in radiation intensity (and/or wavelengths) detected by thedevice 594 from exterior of the pants 102 (e.g., looking at the outsideof the engagement seam 88). In one embodiment, the image produced by thedevice 594 is a black-and-white image in which radiation levelvariations are depicted in varying grayscale levels. Alternatively, suchvariations may be depicted in the image in another manner, such as inthe form of color variations. The image capturing device 594 is inelectrical communication with the inspection system control and may beoperated continuously or it may be shuttered at a speed corresponding tothe intermittent operation of the radiation source 582 to irradiate theengagement seam 88.

[0173] The image capturing device 594 shown in FIG. 24 is a visioninspection camera capable of detecting visible and ultraviolet radiationas well as infrared radiation at wavelengths up to about 1200nanometers. Examples of hardware that may be used are Cognex Checkpointsystems available from Cognex Corporation of Natick, Mass. One is aCheckpoint 800 system using two Sony XC-75 cameras, and another is aCheckpoint II (82411) system using a Dalsa SP-14 line scan camera.However, it is understood that other image capturing devices may used,such as line scan cameras capable of building an image one line at atime from detected radiation as the pants 102 are is conveyed past thedevice, as well as any other device capable of producing a one, two orthree dimensional image from detected radiation, without departing fromthe scope of this invention.

[0174] The image capturing device 594 may also be provided with a filter(not shown) for filtering unwanted wavelengths of radiation, includingthose in the infrared and/or other spectrums, as desired. Such filtersinclude low-pass filters which remove radiation above a predefinedwavelength, high-pass filters which remove radiation below a predefinedwavelength, band-pass filters which remove all radiation except thathaving a wavelength within a predefined range, and combinations thereof.One or more of these filters may be useful for removing ambient,scattered, or even incident radiation from the image captured by theimage capturing device 594. For example, the image capturing device 594of the illustrated embodiment for detecting infrared radiation isdesirably provided with a filter for removing (i.e., blocking)radiation, such as ambient and/or scattered radiation, having awavelength of or below about 830 nanometers (e.g., a high pass filterhaving a nominal value of about 830 nanometers), including visible andultraviolet radiation. Alternatively (or additionally), one or moreshrouds (not shown) may surround the device 594 to shield the devicefrom, e.g., extraneous radiation sources such as ceiling lights, naturallight, etc.

[0175] Now referring back to FIGS. 13 and 19, the seaming section 250can also comprise a pair of rollers 578 mounted for rotation onrespective axles (not shown) which are secured to opposite sides of thelower alignment conveyor 258 immediately downstream of the side paneltransfer devices 430, e.g., between the downstream ends 444 of the sidepanel transfer devices and the upstream ends 550 of the support members548. The rollers 578 are sized and positioned vertically for closelyspaced relationship with the upper alignment conveyor 256 to define nips580 (one of which is shown in FIG. 19) therebetween through which theengagement seams 88 pass following initial engagement of the respectivefastening components 84, 82 of the side panels 34, 134. As an example,the rollers 578 of the illustrated embodiment have an outer diameter ofabout three inches, a face (e.g., width) of about 2.75 inches and touchto form a nip with the upper alignment conveyor 256. Alternatively, therollers 578 and the upper conveyor 256 could be separated by a distanceof up to and about 5 mm. However, it is understood that the position ofeach roller 578 relative to the upper alignment conveyor 256 may beselectively adjusted to vary the size of the nip, and hence thesqueezing pressure applied by the roller to the engagement seam 88. Itis also contemplated that the rollers 578 may be omitted altogetherwithout departing from the scope of this invention. A correspondingroller (not shown) may be disposed within the upper alignment conveyor256 in contact with the conveyor belt 266 and in opposed relationshipwith the rollers 578 to provide a corresponding bearing surface for therollers 578.

[0176] In operation, the partially assembled and folded training pants102 are received from the folding section 200 into the upstream end ofthe seaming section 250 generally in the configuration shown in FIG. 10,e.g., with the front waist region 22 of the absorbent chassis 32 foldedover the back waist region 24 and the front and back side panels 34, 134extending laterally out from the front and back waist regions in opposedrelationship with each other. The front side panel 34 is drawn againstthe upper alignment conveyor 256 in an outstretched configuration, withthe fastening component 84 of the front side panel facing up toward theupper alignment conveyor. An outer portion of the back side panel 134 isdrawn through the slot 342 of the positioning device 330 into theinternal flow chamber 340 thereof. At the downstream locationillustrated in FIG. 15, the positioning device 340 has repositioned theback side panel 134 such that the fastening component 82 is laterallynearer the machine centerline. Vacuum is inhibited from drawing alaterally outward portion of the front side panel 34, including thefastening component 84, against the upper alignment conveyor, such as byclosing off laterally outer holes 269 of the vacuum cover plate 264. Asa result, the laterally outward portion of the front side panel 34 tendsto drop, due to gravity, away from the upper alignment conveyor 256 andfolds over a folding finger 267.

[0177] The upper alignment conveyor 256 can alternatively provide auniform or nonuniform vacuum profile in the cross machine direction. Inparticular embodiments, the upper alignment conveyor 256 can draw anonuniform vacuum in the cross-machine direction. Specifically, theupper alignment conveyor 256 can draw a concentrated vacuum at laterallyoutward regions thereof as well as in a central region disposed betweenthe laterally outward regions. The laterally outward regions can bepositioned such that they correspond to locations of the front sidepanels 34 immediately laterally inward from the locations of thefastening components 84. The concentrated vacuum adjacent the insideedge of the fastening components 84 can encourage the inside edgethereof to generally function as a hinge point for folding. Theconcentrated vacuum can be formed by a plurality of slots or an increasein the number of apertures in the vacuum cover plate 264, by separatevacuum chambers, or the like. The focused vacuum in the central regioncan reduce energy consumption and lessen draw of the back side panels134 toward the upper alignment conveyor 256.

[0178]FIG. 16 illustrates the training pants 102 at a locationdownstream of that shown in FIGS. 14 and 15. The laterally outwardportion of the front side panel 34 has been folded through approximately180 degrees by a suitable panel folding device (not shown) such that thefastening component 84 of the front side panel is now facing down ingenerally opposed relationship with the fastening component 82 of theback side panel 134. The panel folding device (not shown) acts on thelaterally outward portion of the front side panel 34 after the panel isfolded down over the folding finger 267 and can comprise, for example,one or more air nozzles (not shown) which blow the laterally outwardportion of the front side panel 34, including the initiallyoutward-facing fastening component 84, to a horizontal orientationdirected toward the center line of the upper alignment conveyor 256. Thepanel folding device can operate on a continuous or timed intermittentbasis, and can progressively fold the side panel 34 or fold the sidepanel as a single unit. The panel folding device can alternativelycomprise other mechanisms for creating a suitable force to fold orassist to fold the front side panel 34. For example, the panel foldingdevice can comprise folding boards or skis which fold the front sidepanel through 180 degrees; a helical surface that pushes the front sidepanel into the folded configuration; or the like. Once folded inward,the folded portion of the front side panel 34, including the fasteningcomponent 84, is drawn against the upper alignment conveyor 256 tomaintain the folded configuration of the front side panel.

[0179] Upon reaching the location shown in FIG. 16, the side paneltransfer device 430 intersects the downstream end 336 of the positioningdevice 330 such that the portion of the back side panel 134corresponding to the fastening component 82 is supported by the sidepanel transfer device as the back side panel exits the positioningdevice. At this location, the fastening components 82, 84 are inopposed, vertically spaced relationship with each other. The side paneltransfer device 430 elevates the fastening component 82 of the back sidepanel 134 generally in a “z-direction” perpendicular to the machinedirection 108 while the remaining extent of the back side panel hangsgenerally limp between the lower alignment conveyor 258 and the transferdevice. Further downstream, as shown in FIG. 17, the fastening component82 of the back side panel 134 has been elevated further up toward thefastening component 84 of the front side panel 34. The rectangular plate532 of the support assembly 530 extends inward from the side paneltransfer device 430 over the back side panel 134 to separate thefastening components 82, 84.

[0180] Finally, upon reaching the downstream end 444 of the side paneltransfer device 430 (FIG. 18), the fastening component 82 of the backside panel 134 has been elevated into engagement with the fasteningcomponent 84 of the front side panel 34 to define the engagement seam88. As a result, the interior space 51 of the pants is now bounded inpart by the engagement seam 88 and in part by the opposed portions ofthe front and back side panels 34, 134 extending on opposite sides ofthe engagement seam. The support assembly bar 542 is thus positionedwithin the interior space 51 of the pants 102 generally verticallybetween the front and back side panels 34, 134 and laterally between thelower alignment conveyor 258 and the engagement seam 88 upon connectionof the fastening components 82, 84. The connected fastening components82, 84 are urged together upon passing between the nip defined by thedownstream end 444 of the transfer device 430 and the upper alignmentconveyor 256 to facilitate increased engagement between the fasteningcomponents as the training pants 102 are conveyed further downstream.The training pants 102 are then transported downstream past the roller578 whereby the engaged fastening components 82, 84 pass through the nip580 between the roller and the upper alignment conveyor 256 as shown inFIG. 19 to further urge the fastening components together. For example,the squeezing pressure applied upon passing the fastening components 82,84 through the nip 580 may be approximately 1 to 50 pounds, moresuitably from about 5 to about 20 pounds.

[0181] Downstream of the roller 578, the pair of training pants 102 istransported past the upstream end 550 of the support member 548. FIG. 20illustrates the side panels 34, 134 at a location along the tapered leadportion 564 of the support member 548. At this location, vacuum drawingthe folded portion of the front side panel 34 to the upper alignmentconveyor 256 is substantially reduced to release the fastening component84 from being drawn toward the upper alignment conveyor. As a result,the fastening component 84 of the front side panel 34 hangs down fromthe upper alignment conveyor 256 and supports the back side panel 134 ina generally limp configuration via engagement between the fasteningcomponents 82, 84. In the illustrated embodiment, the back side panel134 contacts the bottom wall 560 and lower corner 562 of the supportmember 548 at the tapered lead portion 564 thereof and is positionedsubstantially below the lower alignment conveyor 258 and the back waistregion 24 of the absorbent chassis 32. However, it is contemplated thatthe back side panel 134 may hang down below the tapered lead portion 564of the support member 548 at the location shown in FIG. 20.

[0182] Finally, the training pants 102 are conveyed further downstreamover the main portion 566 of the support member 548 as shown in FIG. 21.Based on the vertical and lateral positioning of the support member 548relative to the upper and lower alignment conveyors 256, 258 (and hencethe absorbent chassis 32), as well as the orientation andcross-sectional dimensions of the main portion 566 of the supportmember, the front and back side panels 34, 134 contact the supportmember and are generally expanded (e.g., pulled or otherwise spacedapart) outward, such as laterally and/or vertically, relative to theabsorbent chassis and pulled taut around the support member.

[0183] More particularly, the front side panel 34 is expanded by thesupport member to extend laterally out over the top wall 552 of thesupport member 548 and down over the upper corner 558 such that thefastening component 84 of the front side panel (and hence the engagementseam 88) is in opposed relationship with the diffuser plate 588 of theangled outer side wall 556. The back side panel 134 is expanded toextend below the bottom wall 560 of the support member 548 in spacedrelationship with the front side panel 34, and up over the lower corner562 of the support member. Expanding the side panels 34, 134 relative tothe absorbent chassis in this manner substantially straightens, or pullsthe side panels taut at the engagement seam 88 and positions theengagement seam in generally opposed relationship with the diffuserplate 588. More particularly, tensioning the side panels 34, 134 aroundthe support member 548 urges the side panels 34, 134 to lie generallyflat on the diffuser plate 588 at the engagement seam 88. Pressurizedfluid exhausted from the air bar 570 is directed to impact at least oneof the side panels 34, 134 at the engagement seam 88 to urge theengagement seam in toward the diffuser plate 588 to further urge thefastening components 82, 84 together.

[0184] Tensioning the side panels 34, 134 also pulls the engagedfastening components 82, 84 in opposite directions, e.g., by applying apulling force to the fastening component of the front side panel 34generally upward along the side wall 556 and applying an oppositepulling force to the fastening component of the back side panel 134generally downward along the side wall as indicated by the directionalarrows in FIG. 21. As a result, one of the fastening components 82, 84is urged to slide relative to the other fastening component, and moreparticularly in the illustrated embodiment the fastening components areurged to slide relative to each other. The tensioning thus generates ashear stress at the engagement seam 88 to promote increased engagementbetween the fastening components 82, 84. For example, where thefastening components 82, 84 are hook and loop fasteners, generating ashear stress at the engagement seam 88 urges sliding movement of onefastening component relative to the other such that the hooks becomefurther embedded or otherwise entangled in the loops, therebystrengthening the engagement between the fastening components. Where thebase material of the loop fastener is constructed of an elasticmaterial, the applied shear stress may alternatively, or mayadditionally, result in stretching (which is also broadly consideredherein as a sliding movement) of the loop fastener relative to the hookfastener, thereby increasing the spacing between the loops to allow thehooks to embed deeper therein.

[0185] With the front and back side panels 34, 134 expanded out over themain portion 566 of the support member 548 so that the engagement seam88 lies generally flat on the diffuser plate 588, the inspection controlsystem operates the radiation source 582 to emit radiation. Radiationfrom the radiation source 582 diffuses through the diffuser plate 588toward the engagement seam 88 to irradiate the side panels 34, 134 atthe engagement seam from within the interior space 51 of the pants 102.The inspection control system also operates the image capturing device594 (FIG. 24) to detect radiation transmitted outward through theengagement seam 88 to thereby capture an image of the engagement seam.The image is then processed and analyzed by a suitable image analyzer(not shown), such as is well known in the art.

[0186] The image obtained from the image analyzer at the secondinspection location is analyzed to determine the position B of the datumline 82 a (see FIGS. 25-27) in the first fastening component, made ofloop material, which as previously mentioned is in the form of a bondline which is visible to the image capturing device 594 through thefolded training pant, and the position C of the inner edge 84 a of thesecond fastening component 84, made of hook material, which will also bevisible to the image capturing device since it will appear darker thanthe surrounding material. The distance (B−C) between the datum line 82 aand the inner edge of the hook material 84 a is then determined and thisdistance is assessed in relation to the distance (A−B) between the datumline 82 a and the outer edge 82 b of the loop material obtained from theimage capturing device at the first inspection location to determine ifthe hook and loop material of the first and second fastening components82,84 are properly aligned based on the following equation:

A−C=|(A−B)|±|(B−C)|

[0187] add (if B is located between A and C) or subtract (if B is notlocated between A and C) where

[0188] A=loop material edge 82 b,

[0189] B=datum line 82 a, and

[0190] C=hook material edge 84 a.

[0191] To be sure that the data for a given training pants 102 takenfrom the first inspection location is properly paired to the data forthat same training pant 102 taken from the second inspection location,the software used to make the analysis must be timed to the movement ofthe assembly line of the manufacturing process. This can be done bysimply taking into account the number of training pants between thefirst and second inspection locations and buffering the data for thatnumber of pants being analyzed.

[0192] Since the alignment between the first and second fasteningcomponents 82,84 need not be exact, a predetermined range of acceptablevariations in either direction from the datum line 82 a is establishedand the results of the calculation (A−C) made using the information fromthe first and second inspection locations is compared to this range todetermine if it is within that acceptable range. Locating the separationof the edges of the first and second fastening components 82, 84assesses the amount of overlap of the fastening components, which isimportant in determining if a good connection of the components has beenachieved. If it is not, then the information can be used to cull thetraining pant from the manufacturing process as unacceptable.

[0193]FIG. 25 is a cross-section of a second embodiment of a seamingsection of apparatus of the present invention. The seaming section ofthis second embodiment is similar to that of the first embodiment exceptthat the support assembly 630 further comprises an air bar, generallyindicated at 670, positioned laterally inward of the bottom wall 660 ofthe support member 648. Exhaust openings 676 (one of which is shown inFIG. 25) of the air bar 670 are positioned so as to direct pressurizedfluid, such as air, exhausted therefrom to impact the portion of theback side panel 134 extending between the back waist region 24 of theabsorbent chassis 32 and the bottom wall 660 of the support member 648.The pressurized fluid urges the back side panel 134 to become tautaround the bottom wall 660 and lower corner 662 of the support member648. As a result, the front side panel 34 is pulled taut against the topwall 652 and upper corner 658 of the support member 648 to thereby urgethe engagement seam 88 in toward the diffuser plate 688 to lie flat onthe plate and to generate a shear stress at the engagement seam 88. Itis contemplated that the fluid pressure of fluid exhausted from the airbar 670 may be selectively adjusted to control the tension in the sidepanels 34, 134.

[0194] While the support member 548, 648 of the illustrated embodimenthas a cross-section generally in the shape of the numeral “7” so thatthe engagement seam 88 lies against a flat surface (e.g., the side wall556, 656) upon tensioning of the front and back side panels 34, 134, itis contemplated that the support member may have a cross-section ofgenerally any shape, such as circular (e.g., such as by using a roller),semi-circular, polygonal, U-shaped, C-shaped or any other suitableshape. The support member 548, 648 may also be oriented vertically(e.g., normal to the machine direction) instead of longitudinally. Also,the side panels 34, 134 need not lie on the support member 548, 648,diffuser plate 588, 688 or other flat surface upon tensioning of thefront and back side panels 34, 134 at the engagement seam, but mayinstead remain free from contact with any structure without departingfrom the scope of this invention as long as the engagement seam isexposed to radiation emitted within the interior space 51 of the pants102.

[0195] Moreover, the length of the support member 548, 648 over whichthe engagement seam 88 is conveyed may be substantially shorter than thelength of the engagement seam so that only a portion of the engagementseam is conveyed over the support member at any given time. In thismanner, the fastening components 82, 84 would tend to bend, or flex atthe engagement seam 88 as the fastening components are conveyed over thesupport member 548, 648 to further work the fastening componentstogether. It is also understood that the shear stress applied to theengagement seam 88 may alternatively, or may additionally, be generatedin the machine direction (e.g., longitudinally) in which the trainingpants are transported through the seaming section, such as by applying alongitudinally oriented force (e.g., pulling, friction, etc.) to one ofthe fastening components 82, 84, or by applying longitudinally oppositeforces to the fastening components.

[0196] While expansion of the training pants 102 of the illustratedembodiment to facilitate inspection of the engagement seam 88 by theinspection system 520 entails expanding the front and back side panels34, 134 outward relative to the absorbent chassis 32, it is understoodthat the pants may be expanded in other suitable manners to straightenor otherwise pull the side panels taut at the engagement seam withoutdeparting from the scope of this invention. For example, while not shownin the drawings, the spacing between the upper and lower alignmentconveyers 256, 258 may substantially increase toward the downstream endof the seaming section 250 following connection of the front and backside panels 34, 134 at the engagement seam 88 to expand the entirearticle at the absorbent chassis 32, e.g., by pulling the front and backwaist regions 22, 24 of the absorbent chassis apart from each other.Increasing the spacing between the front and back waist regions 22, 24causes the connected side panels 34, 134 to generally straightentherebetween to the pull the side panels taut at the engagement seam 88.As a result, the side panels 34, 134 do not need to be supported by thesupport member 548 during inspection of the engagement seam 88.

[0197] Also, the methods and apparatus of the present invention areshown and described herein in connection with making a pair of child'straining pants 20 and inspecting an engagement seam 88 thereof. However,it is understood that the methods and apparatus can be used to make andinspect a variety of articles other than pants 20 where such articlescomprise at least two flexible elements connected together during themaking of such articles in overlapping relationship with other to definean engagement seam as long as the article has an interior space boundedin part by the engagement seam. Such articles may include otherdisposable garments such as diapers, feminine hygiene products,incontinence products, other personal care or health care garments, swimpants, athletic clothing, pants and shorts, as well as other articles,such as balloons, tents, sleeves, cigarette packages, bags, and thelike, whether such articles are disposable or not and whether sucharticles are absorbent or not.

[0198] The data acquisition and comparison methods disclosed herein, andspecifically as adopted for use in a manufacturing process for trainingpants and the like, can have wide ranging uses in other environments,especially where information about some aspect of an item is availableat one location and other information about some other aspect of theitem is available at another location and where a comparison of thosedifferent sets of information can provide an inference as to some otheraspect of the item.

[0199] It will be appreciated that details of the foregoing embodiments,given for purposes of illustration, are not to be construed as limitingthe scope of this invention. Although only a few exemplary embodimentsof this invention have been described in detail above, those skilled inthe art will readily appreciate that many modifications are possible inthe exemplary embodiments without materially departing from the novelteachings and advantages of this invention. For example, featuresdescribed in relation to one embodiment may be incorporated into anyother embodiment of the invention. Accordingly, all such modificationsare intended to be included within the scope of this invention, which isdefined in the following claims and all equivalents thereto. Further, itis recognized that many embodiments may be conceived that do not achieveall of the advantages of some embodiments, particularly of the preferredembodiments, yet the absence of a particular advantage shall not beconstrued to necessarily mean that such an embodiment is outside thescope of the present invention.

[0200] When introducing elements of the present invention or thepreferred embodiment(s) thereof, the articles “a”, “an”, “the” and“said” are intended to mean that there are one or more of the elements.The terms “comprising”, “including” and “having” are intended to beinclusive and mean that there may be additional elements other than thelisted elements.

[0201] As various changes could be made in the above constructionswithout departing from the scope of the invention, it is intended thatall matter contained in the above description or shown in theaccompanying drawings shall be interpreted as illustrative and not in alimiting sense.

What is claimed is:
 1. A method for determining the relative placementof components on an article in a manufacturing process, comprising:establishing a datum position on the article; locating the datumposition at a first location in the manufacturing process; determining afirst distance from a first of the components to the datum position atthe first location in the manufacturing process; locating the datumposition on the article at a second location in the manufacturingprocess; locating a second of the components at the second location inthe manufacturing process; determining a second distance from the datumposition in the second location in the manufacturing process to thesecond component at the second location in the manufacturing process;inferring the relative position of the first and second components fromthe first and second determined distances; and comparing the inferredrelative position to a desired range of relative positions to determineif the inferred relative position is within the desired range.
 2. Themethod of claim 1 wherein the datum position is a bond line on aflexible absorbent article.
 3. The method of claim 1 wherein the datumposition is a line on the article.
 4. The method of claim 1 wherein thedatum position is a mark on the article.
 5. The method of claim 1wherein the datum position is an edge of the article.
 6. The method ofclaim 2 wherein the first component is an edge of a first fasteningcomponent secured to the flexible absorbent article and the secondcomponent is an edge of a second fastening component secured in spacedrelation from the first fastening component to the flexible absorbentarticle.
 7. The method of claim 6 wherein the first fastening componentis a loop fastening component and the second fastening component is ahook fastening component.
 8. The method of claim 7 wherein the flexibleabsorbent article is lying in an extended position at the first locationin the manufacturing process and lying in a folded position in thesecond location in the manufacturing process wherein the loop fasteningcomponent and the hook fastening component are disposed inside thearticle and the loop fastening component is juxtaposed with the hookfastening component.
 9. The method of claim 8 wherein a first camera isused to determine the location of the datum position and the edge of theloop fastening component in the first location in the manufacturingprocess and a second camera is used to determine the location of thedatum position and the edge of the hook fastening component in thesecond location in the manufacturing process.
 10. The method of claim 9wherein a radiation source is provided on the opposite side of theflexible absorbent article from the second camera at the second locationin the manufacturing process.
 11. The method of claim 10 wherein thecamera is on the side of the flexible absorbent article adjacent theloop fastening component and the radiation source is on the side of thearticle adjacent the hook fastening component.
 12. The method of claim11 wherein the bond line forms at least part of a bond between the loopfastening component and the flexible absorbent article.
 13. The methodof claim 12 wherein inferring the relative position of the firstcomponent and the second component at the second location comprisesutilizing the following equation: A−C=|(A−B)|±|(B−C)|wherein A is thelocation of the edge of the loop material, B is the location of thedatum position, C is the location of the edge of the hook material, A−Crepresents a distance between the edges of the loop and hook material,A−B represents the first distance and B−C represents the seconddistance, the first and second distances being added when B is locatedbetween A and C and being subtracted when B is not located between A andC; and wherein comparing the inferred relative position comprisescomparing the distance A−C to a desired range to determine if it fallswithin it.
 14. Apparatus for constructing an article from a plurality ofcomponents and determining if at least two of the components arepositioned within a desired range of positions, comprising an assemblyline for joining multiple components to form an article, including afirst inspection station for determining a first distance of a first ofthe components on an article being constructed from a datum position onthe article and a second inspection station remote from the firstinspection station and down stream in the assembly line therefrom fordetermining a second distance of the datum position on the article froma second of the components at the second inspection station, and a logiccircuit for comparing the first distance and second distance todetermine the relative locations of the first and second components inthe second inspection station.
 15. The apparatus of claim 14 furthercomprising a first camera at the first inspection station to acquire animage of the location of the datum position and the first component inthe first location in the manufacturing process and a second camera atthe second inspection station to acquire an image of the datum positionand the second component in the second location in the manufacturingprocess.
 16. Apparatus for determining the relative placement ofcomponents on an article in a manufacturing process in reference to adatum position on the article, comprising: means for locating the datumposition and a first of the components at a first location in themanufacturing process; means for determining the distance from the firstcomponent to the datum position at the first location in themanufacturing process; means for locating the datum position and asecond of the components on the article at a second location in themanufacturing process; means for determining the distance from the datumposition in the second location in the manufacturing process to thesecond component at the second location in the manufacturing process;and means for comparing the determined distance from the first componentto the datum position at the first location in the manufacturing processto a predetermined desired range of distances from the datum to thesecond component position in the second location in the manufacturingprocess to determine if this distance is within the desired range. 17.The apparatus of claim 16 wherein the datum position is a bond line on aflexible absorbent article.
 18. The method of claim 17 wherein theapparatus is adapted to hold the flexible absorbent article in anextended position at the first location in the manufacturing process andadapted to hold the flexible absorbent article in a folded position inthe second location in the manufacturing process wherein the first andsecond components are disposed inside the article and the firstcomponent is juxtaposed with the second component.
 19. The apparatus ofclaim 18 wherein said means for locating at the first location comprisesa first camera and said means for locating at the second location is asecond camera.
 20. The apparatus of claim 19 wherein said means forlocating at the second location further comprises a radiation sourceadapted to be located on the opposite side of the flexible absorbentarticle from the second camera at the second location in themanufacturing process.
 21. The apparatus of claim 20 wherein the secondcamera is located relative to the radiation source such that when theflexible absorbent article is at the second location the second camerais on the side of the flexible absorbent article adjacent the loopfastening component and the radiation source is on the side of thearticle adjacent the hook fastening component.